Furniture spring system

ABSTRACT

A furniture spring system, configured to provide a seating surface. The furniture spring system comprising a lid comprising a frame. The frame comprising two opposing frame members and a retention member associated with at least one of the two opposing frame members, a slat extending between the two opposing frame members, the slat comprising an elongate body having a first end and a second end and a catch disposed at the first end or second end, wherein the catch engages the retention member to retain the slat to the frame and the catch is configured to slide back-and-forth relative to the retention member as a portion of the elongate body between the first end and the second end elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. ProvisionalApplication No. 62/806,516, filed on Feb. 15, 2019, entitled INTEGRATEDMANUFACTURING FOR MODULAR FURNITURE, which is incorporated herein in itsentirety by reference.

BACKGROUND The Field of the Invention

The present disclosure relates to furniture and furniture systems. Morespecifically, the present disclosure relates to furniture springsystems.

The Relevant Technology

Spring systems that provide cushioning to furniture items such as beds,couches, and chairs are generally manufactured to be permanently fixedwithin a furniture item. For example, a box spring for a mattressincludes internal springs that are not removable by a user. Also,S-springs or other springs are often integrated into base members ofcouches and chairs to provide added cushioning beneath cushions placedthereon.

Spring systems currently utilized in furniture are limited in a numberof ways. For example, as noted above, spring systems are not removableor replaceable by a user without significant deconstruction of thefurniture item and costly reconstruction. Typically, when a spring in abox spring breaks, it is more economical for the user to throw out thebox spring and buy a new one rather than fix the single broken spring.Also, springs built into couches and chairs are integrated into thefurniture in such a way that replacement of the spring system isdifficult or impossible without damaging the furniture. Thus, as springsystems age and become less firm over time, it is not viable to simplyreplace the spring system.

Furthermore, the cushioning provided by current spring systems are setsuch that the user cannot change the degree of flexion, or “firmness,”of the spring system to alter the provided cushioning effect. Rather,the spring system built into a given furniture item, and thus the degreeof cushioning provided, is predetermined by the manufacturer and cannotbe changed by the user.

However, over time, or as the use of a furniture item changes from oneuser to another, it may be desirable to change the amount of cushioningprovided by a spring system within a furniture item. For example, usersoften have varying opinions on how firm they like their bed, including afirmness of their box spring. Additionally, a user's preference maychange over time. Unfortunately, users need to buy entirely differentbox springs to alter the firmness of their beds. The same applies to thefirmness of spring systems built into couches, chairs, and otherfurniture items.

Furniture items, such as beds, couches, and chairs, can also includebuilt-in storage spaces. For example, a bed may include space within orunderneath the bed frame to store items. Also, couches may includestorage spaces within base components or otherwise underneath cushionsor within ottomans. However, such furniture storage spaces, which areadvantageous to save space and provide extra storage areas within aroom, are constructed in a way that while protecting items within thestorage spaces from damage limit cushioning or firmness variations. Forexample, for a storage space disposed underneath a bed or couch, rigidbarriers to the storage space, such as lids or drawers, are used toprotect items placed inside the storage space. These rigid componentsare placed underneath furniture cushions or mattresses to support userswho sit or lie thereon and can negatively affect the comfort of thefurniture item.

Accordingly, there are a number of problems in the prior art that needto be addressed in the field of furniture and furniture spring systems.

BRIEF SUMMARY OF THE INVENTION

The present disclosure relates to furniture and furniture systems. Morespecifically, the present disclosure relates to furniture springsystems. In one embodiment of the present disclosure, for example, afurniture spring system, includes a lid configured to provide a seatingsurface. The lid includes a frame comprising two opposing frame membersand a retention member disposed on a top surface of at least one of thetwo opposing frame members. The spring system also includes an elongateslat extending between the two opposing frame members. In such anembodiment, the slat has an elongate body with an upper surface, a lowersurface, a first end, a second end, and a flexible middle portionextending between the first end and the second end. The slat alsoincludes a catch disposed at the first or second end. The catch engagesthe retention member to retain the slat to the frame and is configuredto slide back-and-forth relative to the retention member as the middleportion elastically flexes downward and upward in response to forcesintermittently pushing downward on the slat during use.

Furniture spring systems described herein solve a number of problems.For example, furniture spring systems of the present disclosure providesupport to users sitting or lying thereon while protecting items thatmay be placed or stored below. In some configurations, spring systemsdescribed herein are modular. In some configurations, the spring systemsdescribed herein are easily replaceable without requiring deconstructionof other furniture components. In some configurations, spring systemsdescribed herein are adjustable so that users can customize the firmnessor size of the spring system to suit their preferences or spacing needs.In some embodiments, the slats of the spring system can be extendable orcontractable in order to make a furniture system a different size. Insome configurations, the spring systems described herein can be at leastone of moveable, replaceable, and adjustable. Embodiments of theinvention, such as the examples disclosed herein, may be beneficial in avariety of respects.

In one embodiment of the present disclosure, a furniture spring systemincludes a lid configured to provide a seating surface and an elongateslat. The lid includes a frame having two opposing frame members, eachframe member having a chamfered top inner edge, and a retention memberdisposed on at least one of the two opposing frame members. The elongateslat extends between the two opposing frame members and includes anelongate body having an upper surface, a lower surface, a first end, asecond end, and a flexible middle portion extending between the firstend and the second end. The elongate slat also includes a catch disposedat the first or second end, the catch engaging the retention member toretain the slat to the frame. The chamfered top inner edge of each framemember is configured to allow the slat to flex downward in response to aload applied thereon without the frame members impeding a downwarddisplacement of the lower surface of the slat during use.

In one embodiment of the present disclosure, a furniture assemblyincludes a transverse member and a base member. The base member includesa base frame member having a bottom panel, side panels, and upper edgeson the side panels. The base member also includes a lid configured to bemounted on the base frame member. The lid is mounted such that the lidcovers a storage cavity formed within the base frame member. In such anembodiment, the lid includes slats, each slat having an elongate memberand one or more catches that engage retention members of the base framemember.

In one embodiment, a furniture spring system of the present inventioncomprises (i) a lid configured to provide a seating surface, the lidcomprising a frame comprising two opposing frame members and a retentionmember associated with at least one of the two opposing frame members;and (ii) a slat extending between the two opposing frame members, theslat comprising an elongate body having a first end and a second end anda catch disposed at the first end or second end, wherein the catchengages the retention member to retain the slat to the frame and thecatch is configured to slide back-and-forth relative to the retentionmember as a portion of the elongate body between the first end and thesecond end elastically flexes downward and upward in response to forcesintermittently pushing downward on the slat during use.

Another embodiment of a furniture spring system comprises a framecomprising two opposing frame members, and a retention member disposedon at last one of the two opposing frame members, and an elongate slatextending between the two opposing frame members, the slat comprising anelongate body having an upper surface, a lower surface, a first end, asecond end, and a flexible middle portion extending between the firstend and the second end, and a catch disposed at the first end or thesecond end, the catch engaging the retention member to retain the slatto the lid frame.

A furniture assembly of the present invention may comprise (i) atransverse member and (ii) a base member, the base member comprising astorage base and a lid configured to be mounted on a top of the storagebase, such that the lid covers a storage cavity formed within thestorage base, the lid comprising a frame with opposing frame membershaving one or more retention members, and one or more slats, each slathaving an elongate member and one or more catches that engage the one ormore retention members of the frame.

In another embodiment, a furniture spring system comprises, (i) a lidconfigured to be mounted onto (ii) a base frame of a furniture base, thelid configured to provide a seating surface, the lid comprising, a framecomprising two opposing frame members, and a plurality of retentionmembers associated with each of the two opposing frame members, aplurality of slats extending between the two opposing frame members,each of the slats comprising an elongate body having a first end and asecond end and first and second catches disposed at the first end andsecond end, respectively, of the elongate body, wherein each catchengages a retention member to retain the corresponding slat to theframe, and wherein each catch of a slat is configured to slideback-and-forth relative to the corresponding retention member as aportion of the elongate body between the first end and the second endelastically flexes downward and upward in response to forcesintermittently pushing downward on the slat during use.

Principles of the present invention can also be applied to mattressesand sleeping systems, making the systems more efficient, useful, andenabling the use of various parts in various different sizes ofmattresses and bedding systems.

In one embodiment, a modular mattress system of the present inventioncomprises a plurality of mattress modules configured to form a firstmodular mattress of a first selected geometry and being reconfigurableto form a second modular mattress of a second selected geometry, each ofthe mattress modules having a width (x) and a length (y), wherein thelength (y) is substantially equal to two times the width (x); a bedcasing (e.g., a rigid bed casing) configured to secure the plurality ofmattress modules to form a completed mattress; and a mattress toppersized and shaped to substantially cover the completed mattress andprovide additional cushioning to a user.

Manufactured components of the present invention may include basemembers, and/or transverse members, e.g., for use in assembling a chair,couch, or the like, or other furniture components, methods, ortechnology, such as those disclosed in U.S. Pat. No. 7,213,885 entitledMODULAR FURNITURE ASSEMBLY, incorporated herein by reference in itsentirety. The modular furniture components and methods disclosed in thepresent application may also be used in connection with numerousfurniture assemblies, e.g., such as, but not limited to, any similar tothose disclosed in (i) U.S. Pat. No. 9,277,826, entitled MOUNTINGPLATFORM FOR MODULAR FURNITURE ASSEMBLY, (ii) U.S. Pat. No. 8,783,778,entitled MOUNTING PLATFORM FOR MODULAR FURNITURE ASSEMBLY, (iii) U.S.Pat. No. 7,963,612 entitled MODULAR FURNITURE ASSEMBLY, (iv) U.S. Pat.No. 7,547,073, entitled MODULAR FURNITURE ASSEMBLY, (v) U.S. Pat. No.7,213,885 entitled MODULAR FURNITURE ASSEMBLY, (vi) U.S. Publication No.2017/0367486 entitled MODULAR FURNITURE ASSEMBLY CORNER SEATING SYSTEM,(vii) U.S. Pat. No. 10,212,519 entitled ELECTRONIC FURNITURE SYSTEMSWITH INTEGRATED INTERNAL SPEAKERS, (viii) U.S. Pat. No. 10,236,643entitled ELECTRICAL HUB FOR FURNITURE ASSEMBLIES, (ix) U.S. Pat. No.10,143,307 entitled FURNITURE SYSTEM WITH RECLINER ASSEMBLY, and (x)U.S. Pat. No. 10,123,621 entitled FURNITURE SYSTEM RECLINER ASSEMBLYWITH SLED RAILS, each of which is incorporated herein by reference inits entirety.

These and other objects and features of the present invention willbecome more fully apparent from the following description and appendedclaims or may be learned by the practice of the invention as set forthhereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other advantages and features of thepresent invention, a more particular description of the invention willbe rendered by reference to specific embodiments thereof which areillustrated in the appended drawings. It is appreciated that thesedrawings depict only illustrated embodiments of the invention and aretherefore not to be considered limiting of its scope. The invention willbe described and explained with additional specificity and detailthrough the use of the accompanying drawings in which:

FIG. 1 illustrates an embodiment of a modular furniture system in theform of a couch, including two bases, a number of transverse members,and number of cushions on top of the bases, according to the presentdisclosure;

FIGS. 2A and 2B illustrate exploded views of another embodiment of amodular furniture system in the form of an armchair, including a storagebase having a lid with a spring system extending thereacross and aplurality of couplers configured to hold the various transverse membersto the base, according to the present disclosure;

FIG. 3A illustrates an exploded view of an embodiment of a furniturespring system disposed over a furniture base, according to the presentdisclosure;

FIG. 3B illustrates the furniture base of FIG. 3A according to thepresent disclosure;

FIG. 4A illustrates a partially exploded view of an embodiment of afurniture spring system disposed over a furniture base, according to thepresent disclosure;

FIG. 4B illustrates an assembled view of the furniture spring system ofFIG. 4A;

FIG. 4C illustrates a view of an embodiment of a furniture spring systemdisposed over a furniture base in an open position, according to thepresent disclosure;

FIG. 4D illustrates a view of the furniture spring system of FIG. 4C ina closed position;

FIG. 5A illustrates a close-up view of a portion of the spring systemillustrated in FIG. 3, as indicated in FIG. 3, according to the presentinvention;

FIG. 5B illustrates a close-up view of a portion of the spring systemillustrated in FIG. 3, as indicated in FIG. 3, according to the presentinvention;

FIG. 6 illustrates a close-up view of a portion of the spring systemillustrated n FIG. 4B, as indicated in FIG. 4B, according to the presentdisclosure;

FIG. 7 illustrates an exploded view of another embodiment of a springsystem including a furniture cushion, according to the presentdisclosure;

FIG. 8A illustrates a perspective view of an embodiment of a springsystem, according to the present disclosure;

FIG. 8B illustrates a perspective view of the spring system illustratedin FIG. 8A with a load applied downwardly on the spring system;

FIG. 9A illustrates a cross-sectional view of the spring systemillustrated in FIG. 8A along plane 9A-9A indicated in FIG. 8A;

FIG. 9B illustrates a cross-sectional view of the spring systemillustrated in FIG. 8B along plane 9B-9B indicated in FIG. 8B;

FIG. 10 illustrates an exploded view of another embodiment of a springsystem including a furniture cushion, according to the presentdisclosure;

FIG. 11A illustrates a perspective view of an embodiment of a springsystem, according to the present disclosure;

FIG. 11B illustrates a perspective view of the spring system illustratedin FIG. 11A with a load applied downwardly on the spring system;

FIG. 12A illustrates a cross-sectional view of the spring systemillustrated in FIG. 11A along plane 12A-12A indicated in FIG. 11A;

FIG. 12B illustrates a cross-sectional view of the spring systemillustrated in FIG. 11B along plane 12B-12B indicated in FIG. 11B;

FIG. 13 illustrates an exploded view of another embodiment of a springsystem including a furniture cushion, according to the presentdisclosure;

FIG. 14A illustrates a perspective view of an embodiment of a springsystem, according to the present disclosure;

FIG. 14B illustrates a perspective view of the spring system illustratedin FIG. 14A with a load applied downwardly on the spring system;

FIG. 15A illustrates a cross-sectional view of the spring systemillustrated in FIG. 14A along plane 15A-15A indicated in FIG. 14A;

FIG. 15B illustrates a cross-sectional view of the spring systemillustrated in FIG. 14B along plane 15B-15B indicated in FIG. 14B;

FIG. 16 illustrates an exploded view of another embodiment of a springsystem including a furniture cushion, according to the presentdisclosure;

FIG. 17A illustrates a perspective view of an embodiment of a springsystem, according to the present disclosure;

FIG. 17B illustrates a perspective view of the spring system illustratedin FIG. 17A with a load applied downwardly on the spring system;

FIG. 18A illustrates a cross-sectional view of the spring systemillustrated in FIG. 17A along plane 18A-18A indicated in FIG. 17A;

FIG. 18B illustrates a cross-sectional view of the spring systemillustrated in FIG. 17B along plane 18B-18B indicated in FIG. 17B;

FIG. 19 illustrates an exploded view of another embodiment of a springsystem including a furniture cushion, according to the presentdisclosure;

FIG. 20A illustrates a perspective view of an embodiment of a springsystem, according to the present disclosure;

FIG. 20B illustrates a perspective view of the spring system illustratedin FIG. 20A with a load applied downwardly on the spring system;

FIG. 21A illustrates a cross-sectional view of the spring systemillustrated in FIG. 20A along plane 21A-21A indicated in FIG. 20A;

FIG. 21B illustrates a cross-sectional view of the spring systemillustrated in FIG. 20B along plane 21B-21B indicated in FIG. 20B;

FIG. 22A illustrates an exploded view of an embodiment of an integratedlid-cushion assembly including a spring system, according to the presentdisclosure;

FIG. 22B illustrates an assembled view of the integrated lid-cushionassembly of FIG. 22A;

FIG. 23A illustrates a perspective view of a modular mattress systemaccording to the present disclosure;

FIG. 23B illustrates an exploded view of the modular mattress system ofFIG. 23A;

FIG. 24 illustrates a modular mattress system according to one or moreimplementations of the present disclosure, wherein variousconfigurations of mattress modules are utilized to form beds ofdifferent dimensions;

FIG. 25 illustrates a modular mattress system according to one or moreimplementations of the present disclosure, wherein variousconfigurations of mattress modules are utilized to form beds ofdifferent dimensions;

FIG. 26 illustrates a modular mattress system according to one or moreimplementations of the present disclosure, wherein variousconfigurations of mattress modules are utilized to form beds ofdifferent dimensions;

FIG. 27 illustrates a modular mattress system according to one or moreimplementations of the present disclosure, wherein variousconfigurations of mattress modules are utilized to form beds ofdifferent dimensions;

FIG. 28 illustrates a modular mattress system according to one or moreimplementations of the present disclosure, wherein variousconfigurations of mattress modules are utilized to form beds ofdifferent dimensions;

FIG. 29 illustrates a top plan view of a modular mattress systemaccording to one or more implementations of the present disclosure.

FIG. 30 illustrates a perspective view of a modular mattress systemaccording to one or more implementations of the present disclosure.

FIG. 31 illustrates a perspective view of a modular mattress systemaccording to one or more implementations of the present disclosure,wherein sidewalls are added to the bed base to increase the size of themodular mattress system.

FIG. 32A illustrates a perspective view of a casing of a modularmattress system in a closed position according to one or moreimplementations of the present disclosure.

FIG. 32B illustrates a perspective view of a casing of a modularmattress system in an open position according to one or moreimplementations of the present disclosure.

FIG. 33A illustrates a side, cross-sectional view of a casing of amodular mattress system as applied to a number of mattress modulesaccording to one or more implementations of the present disclosure.

FIG. 33B illustrates a top plan view of a casing of a modular mattresssystem as applied to a number of mattress modules according to one ormore implementations of the present disclosure.

FIG. 33C illustrates a bottom plan view of a casing of a modularmattress system as applied to a number of mattress modules according toone or more implementations of the present disclosure.

FIG. 34A illustrates a schematic top plan view of an embodiment of amodular bed frame according to one or more implementations of thepresent disclosure.

FIG. 34B illustrates a schematic top plan view of the bed frame of FIG.34A in an extended position according to one or more implementations ofthe present disclosure.

FIG. 35 illustrates a mattress system according to one or moreimplementations of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present disclosure relates to furniture and furniture systems. Morespecifically, the present disclosure relates to furniture springsystems. For example, in at least one embodiment of the presentdisclosure, a furniture spring system includes a lid configured toprovide a seating surface. The lid includes a frame having two opposingframe members and a retention member disposed on a top surface of atleast one of the two opposing frame members. The spring system alsoincludes an elongate slat extending between the two opposing framemembers. The slat has an elongate body with an upper surface, a lowersurface, a first end, a second end, and a flexible middle portionextending between the first end and the second end. The slat alsoincludes a catch disposed at the first or second end. The catch engagesthe retention member to retain the slat to the frame and is configuredto slide back-and-forth relative to the retention member as the middleportion elastically flexes downward and upward in response to forcesintermittently pushing downward on the slat during use.

Furniture spring systems described herein solve a number of problems.For example, furniture spring systems of the present disclosure providesupport to users sitting or lying thereon while protecting items thatmay be placed or stored below. In some configurations, spring systemsdescribed herein are modular. In some configurations, spring systemdescribed herein are easily replaceable without requiring deconstructionof other furniture components. In some configurations, spring systemsdescribed herein are adjustable so that users can customize the firmnessof the spring system to suit their preferences. In some embodiments, theslats of the spring system can be extendable. In some configurations,the spring systems described herein can be at least one of moveable,replaceable, and adjustable.

Embodiments of the invention, such as the examples disclosed herein, maybe beneficial in a variety of respects. For example, and as will beapparent from the present disclosure, one or more embodiments of theinvention can provide one or more advantageous and unexpected effects,in any combination, some examples of which are set forth below. Itshould be noted that such effects are neither intended, nor should beconstrued, to limit the scope of the claimed invention in any way. Itshould further be noted that nothing herein should be construed asconstituting an essential or indispensable element of any invention orembodiment. Rather, various aspects of the disclosed embodiments may becombined in a variety of ways so as to define yet further embodiments.Such further embodiments are considered as being within the scope ofthis disclosure. As well, none of the embodiments embraced within thescope of this disclosure should be construed as resolving, or beinglimited to the resolution of, any particular problem(s). Nor should anysuch embodiments be construed to implement, or be limited toimplementation of, any particular technical effect(s) or solution(s).Finally, it is not required that any embodiment implement any of theadvantageous and unexpected effects disclosed herein.

Turning now to the Figures, FIG. 1 illustrates an embodiment of amodular furniture system 10 in the form of a couch, including two bases12, a number of transverse members 14, and number of cushions 16 onbases 12. The two bases 12 and the transverse members 14 are securedtogether via the couplers 18, which are generally hidden from view asdepicted in FIG. 1, but shown in the exploded view of the furnituresystem 10 b in FIG. 2. The furniture system 10 is modular in that thebases 12, the transverse members 14, and the cushions 13 can be added,subtracted, and repositioned relative to one another to form any numberof furniture configurations. For instance, while FIG. 1 illustrates thefurniture system 10 arranged to form a two-seated couch, the size andconfiguration of the furniture system can be varied based upon theparticular needs of a user. For instance, in another configuration, thefurniture system 10 can include additional bases 12 and transversemembers 14 to form a larger couch, an L-shaped sectional, or the like.In still another configuration, such as illustrated in FIG. 2, a singlebase 12 is combined with the transverse members 14 and at least onecushion 16 to form a chair, as will be described in more detailhereinafter. In still other configurations, one or more bases 12 may beconfigured without any transverse members 14 to form ottomans, otherseats, and other types of furniture systems. For example, one or morebases 12 and cushions 13 can be configured together to form a bed,including a box spring comprised of the bases 12 and/or the cushions 13serving as a mattress or other padding.

One or more of the bases 12 of the furniture system 10 can include astorage cavity or space to store items, such as blankets, books,electronics, or other items within the base 12. As such, in thedescription, base and storage base can be used interchangeably to referto the bases of the various furniture systems. In at least oneembodiment, the storage bases can be visually indistinguishable fromnon-storage bases and often improve the aesthetic appearance of thefurniture systems over the non-storage bases. Because the bases 12 canbe rearranged and reconfigured within the furniture system 10, thestorage spaces provided by such bases 12 can be repositioned within afootprint of the furniture system 10 without changing, repositioning, orotherwise reconfiguring the overall footprint of the furniture system10. Stated another way, the location of particular storage spaces withina furniture system 10 can be changed while maintaining a particularfootprint or combination modules forming the furniture system 10.

Turning now to FIGS. 2A and 2B, illustrated is another embodiment of amodular furniture system 10 b in the form of an armchair. Thedescription of the furniture system 10 is also applicable to thefurniture system 10 b, and vice versa.

The furniture system 10 b includes a storage base 12 having a lid 22with a spring system 24, and a cushion 16. A plurality of couplers 18hold the various transverse members 14 to the storage base 12 as theyare disposed within complementary slots 26 formed in the storage base 12and the transverse members 14. For instance, the transverse members 14and the storage base 12 include the slots 26 into which opposing arms ofthe couplers 18 are inserted to secure the storage base 12 to thevarious transverse members 14. The couplers 18 are removable such thatthe storage base 12 and the transverse members 14 can be separated,rearranged, and re-secured together. Alternatively, the base 12 and thetraverse members 14 may be coupled via magnets embedded in one or bothof base 12 and/or traverse members 14, optional with complementaryiron-based coupling plates or connectors. The magnetic coupling assemblyof U.S. Pat. No. 9,277,813 is incorporated herein by reference. In otherconfigurations, other structures can be used to connect the storagebases 12, such as hook and loop fasteners, spring clamps, belts, orother mechanical fasteners or couplers. Additional details for a base orstorage base useable with the spring system 24 can be found in U.S.patent application Ser. No. 16/707,571 entitled “Furniture Storage Base”filed Dec. 9, 2019, the entire disclosure of which is incorporatedherein by this reference.

In at least one embodiment, the lid 22 is configured to be removablefrom the storage base 12 independently of the transverse members 14, asillustrated in FIGS. 2A-4B. For example, once the furniture system 10 bis assembled so that the transverse members 14 are secured to thestorage base 12 via the couplers 18, the lid 22 can be selectivelyremoved from the storage base 12 to provide access to a storage cavity20 defined by an interior space of the storage base 12. This can be donewithout removing any of the transverse members 14 from the storage base12. Likewise, the lid 22 can be placed on top of the storage base 12without altering any other connections of the various furniture systemcomponents. In some embodiments, “on top of a storage base” can includepositioning the lid 22 on an uppermost edge or surface of one or morewalls of the storage base 12. In other embodiments, “on top of a storagebase” can include configurations where the lid 22 is disposed on atleast a portion of the one or more walls. In other embodiments, “on topof a storage base” can include configurations where the lid 22 selectivecontacts at least a portion of the one or more walls, such as when thelid 22 is at least partially disposed within a recess of the storagebase 12, as will be discussed in further detail hereinafter.

To allow the lid 22 to be easily removed from the storage base 12, thelid 22 may not be secured in any way to the storage base 12. Rather, thelid 22 can rest on top of the storage base 12 and can easily be liftedoff. However, in at least one embodiment, the lid 22 can be partially orremovably secured to the storage base 12. For example, in at least oneembodiment, the lid 22 can be removably secured to the storage base 12via one or more clips, clamps, or other securement means along one ormultiple edges of lid 22. In such an embodiment, the lid 22 can beremovably secured to storage base 12 to prevent the lid 22 frominadvertently lifting, sliding off, or otherwise disengaging fromstorage base 12.

Alternatively, in at least one embodiment, the lid 22 is fixed on top ofthe storage base 12 to allow the lid 22 to be pivoted or tilted from thestorage base 12 like a door. For instance, as illustrated in FIGS.4C-4D, the lid 22 is fixed to the storage base 12 via one or more hinges28. Other securement means, including removable securement means thatsecure the lid 22 to the storage base 12 are also contemplated which atleast partially secure the lid 22 to the storage base 12 while stillallowing selective access to the storage cavity 20.

In still other embodiments, the storage base 12 can be a base memberthat does not provide storage space. Rather, the storage base 12 can beconfigured as a typical furniture base member having springs, such asthe spring system 24. Whether the lid 22 is removable or permanentlyfixed to the storage base 12, the lid 22 can still be utilized andfunction as described herein.

In the illustrated embodiments of FIGS. 1A-2A, the lid 22 and thecushion 16 are separate and distinct from one another. The cushion 16sits on top of the lid 22, and/or a portion of the storage base 12,during use and can be freely separated from the lid 22 to provide accessto the storage cavity 20. In at least one other embodiment, the lid 22and the cushion 16 can be removably secured together or integrallyformed with one another such that lifting the cushion 16 also lifts thelid 22 from the storage base 12, such as illustrated in FIGS. 22A-22B.

Turning to FIGS. 3A and 3B, the storage base 12 includes a base frame 30with a recessed member 32 disposed within an interior space 34 of thebase frame 30 and below a top surface 40 of the base frame 30; theinterior space 34 forming a part of the storage cavity 20 (FIG. 2B). Thebase frame 30 includes the walls 36 and a base 38 that bound storagecavity 20. The lid 22 is configured to selectively rest upon therecessed member 32 without impinging on the storage cavity 20. The base38 may optionally be covered or lined with fabric 80 (FIG. 3B), andoptionally removable from a remainder of base frame 30. The fabric 80can be separately removed from base 38 so it might be cleaned.

The recessed member 32 includes an internal chamfered edge 42 thatextends at least partially around a perimeter of the base frame 30 andfrom a surface 44. The internal chamfered edge 42 and the surface 44accommodate the lid 22. The surface 44, and optionally a portion of theinternal chamfered edge 42, includes the slots 26 that receive thecouplers 18 (FIG. 2A). Forming the slots 26 in the surface 44 ratherthan only in the internal chamfered edge 42 separates the couplers 18(FIG. 2A) from a location where the lid 22 rests in the storage base 12.This creates a continuous surface free of obstructions on which the lid22 may be placed, allowing at least a portion of the lid 22 to sitsubstantially flush with the top surface 40 of the base frame 30 toreceive the cushion 16. Slots 26 are at least partially set back fromthe internal chamfered edge 42 to limit interference between the coupler18 (FIG. 2A) and the lid 22 and the coupler 18 (FIG. 2A) and the cushion16. A majority of a depth of the slots 26 are, therefore, positionedbetween the base frame 30 and the internal chamfered edge 42. Inalternate configurations, the slots 26 are formed only in the surface44, without a portion of the slot 26 formed in the internal chamferededge 42 and/or the wall 36 of the base frame 30.

As mentioned previously, the storage cavity 20 or the interior space 34can be defined by the walls 36, the base 38, and the lid 22. The base 38can have an interior-facing surface 70 configured to come into contactwith items stored within the storage base 12 when no fabric 80 isprovided and an exterior-facing surface 72 which can come into contactwith the floor or other surface where the storage base 12 is located.For instance, the base 38 includes feet 74 formed with the base 38. Webs76 extend between the interior-facing surface 70 and the exterior-facingsurface 72 and form venting holes 78 to provide airflow and decrease theweight of the base 38. As illustrated, the webs 76 form concentric ringsand straight members emanating from a common central point, therebyincluding the venting holes 78 of different sizes. While this is oneillustrative pattern of the webs, the base 38 can have differentpatterns of webs where the spacing between adjacent webs can be uniformor non-uniform, with sizes optionally being dependent on the size of theitems to be stored within the storage base 12, and the desired weight ormaterial usage to form the base 38. For example, toddler toys mayinclude large blocks which can be stored in a storage base have a basewith a large grid pattern or larger spacing between adjacent webs, whileolder children might have small toys requiring the base to having asmaller or finer-sized grid pattern.

The base 38 can be formed as monolithic structure with the feet 74 andthe webs 76 formed as one-piece structure. Alternatively, the feet 74can be separate structures from a remainder of base 38, the feet 74being permanently or removably attached to a reminder of the base 38. Inother configurations, less than all of the spaces between adjacent thewebs 76 include the venting holes 76. In still other configurations, thebase 38 may be solid, without the venting holes 78, so as to create asealed compartment without any apertures. In still other configurations,the base 38 can include cross-hatching, patterning, groove formation, orother patterns, with or without venting holes, apertures, etc. In stillother configurations, the Generally, the parts of storage base 12 can beformed as a single monolithic structure, i.e., as a one-piece structure,or alternatively, the parts of storage base 12 may separate pieces andassembled together to form storage base 12 as illustrated and describedherein. Storage base 12 can be fabricated from a polymer, wood, metal,alloys, composites, combinations thereof, or the like.

Returning to FIG. 3A, the lid 22 includes the spring system 24 withassociated slats 50 and frame 52. The frame 52 can be self-balancing inthat a user may be able to drop the frame 52 onto the base 12 and theframe 52 may settle itself into the correct position on the base 12. Thecombination of the supports and structures of the frame 52 allow theframe 52 to maintain its shape under load as the slats 50 flex ordeflect.

As illustrated, the frame 52 has an exterior support 84 and an interiorsupport 86 separated by an upper support 88 and a transition support 90.Both the exterior support 84 and the interior support 86 extend around aperimeter of the frame 52, with the interior support 86 verticallydisplaced relative to the exterior support 84. Upper support 88 extendsfrom the exterior support 84 towards an intermediate support 92 fromwhich the transition support 90 extends to the interior support 86. Thetransition support 90 extends at an angle that approximates the internalchamfered edge 42 of recessed member 32 so the frame 52 can rest withinthe interior space 34.

To reduce overall weight of the frame 52, while maintaining strength andrigidity, the frame 52 includes a number of walls or webs forming spacesor compartments. This allows the frame 52 to be formed as a singlemonolithic structure, i.e., as a one-piece structure, or alternativelyas a number of parts assembled together to form the frame 52.Additionally, the frame 52 can be fabricated from a polymer, wood,metal, alloys, composites, combinations thereof, or the like.

As illustrated in FIGS. 4A and 5A, the upper support 88 includes aplurality of walls or webs 98, with adjacent walls or webs 98,optionally in combination with the intermediate support 92, formingsecuring compartments 100 that accommodate or receive a portion of theslat 50. A portion of the intermediate support 92 between the adjacentwebs 98 form a securing edge 102 to which the slat 50 connects. Thesecuring edge 102 may extend the length of the opposing sides of theframe 52. In some embodiments, the securing edge 102 may extend thelength of all edges of the frame 52. The securing edge 102 may bedefined into the series of securing compartments 100 which may maintainthe slat 50 in a particular position within the spring system 24. Statedanother way, the intermediate support 92 is partitioned into thesecuring edges 102, and associated securing compartments 100, by thewalls or webs 98 extending or running perpendicular or transverse to theexterior support 84 and/or the intermediate support 92. In someembodiments, the walls or webs 98 may be equally spaced in order tomaintain even distribution of the slats 50 within the spring system 24.In other embodiments, the walls or webs 98 may be distributedperpendicular to the securing edge 102 at varying distances to achieve adesired spring system 24 effect.

Transition support 90 also includes a plurality of webs 104 with spaces106. An upper surface of the webs 98 lie in the same plane, while uppersurfaces of the webs 102 lie in another plane transverse to the uppersupport 88. It is understood, however, that the upper surfaces of thewebs 98 need not lie in the same plane and the upper surfaces of thewebs 102 need not lie in the same plane and that plane need not betransverse to the plane associated with the upper support 88.

As illustrated in FIG. 5A, a step 110 is formed between transitionsupport 90 and upper support 80 at a terminal end 112 of the uppersupport 88. Formed on the webs 98 are flanges 114 that extend towardsthe exterior support 84 and are configured to slidably cooperate withthe slat 50 disposed within the securing compartment 100, as will bedescribed in more detail hereinafter. Flange 114, in the illustratedconfiguration, includes an upper flange portion 116 and a lower flangeportion 118. The combination of the flange 114 on each side of the web98 forms a generally polygonal form when viewing terminal end 112 fromwithin a space 120 (FIG. 3A) formed by the interior support 86. It willbe understood that the combination of the flange 114 on each side of theweb 98 can form non-polygonal or combinations of polygonal andnon-polygonal shapes.

As illustrated in FIGS. 2A-3A and 4A-4B, the spring system 24 includesthe slats 50 spanning the frame 52. Each slat 50 is elongate having anelongate body 56 with a first end 58 and a second end 60 that attach theslats 50 to the frame 52. The slats 50 can have a flexible middleportion 62 extending between the first end 58 and the second end 60. Theslats 50 can have an arcuate profile spanning the length of the elongatebody 56 of the slat 50. In some embodiments, an upper surface 64 of theslat 50 may be substantially flat or planer, while a lower surface 66 ofthe slat 50 has an arcuate profile. The upper surface 64 of the slat 50is a side of slat 50 which can come into direct contact with the cushion16 (FIG. 1) when the slat 50 is assembled on the frame 52. Theillustrated spring system 24 can also optionally include fabric or othermaterial spanning the frame 52 over or around the slats 50 or canoptionally include a wooden board or metal board or other materialspanning the frame 52. Additionally, the spring system 24 optionallyincludes material or components configured to support the cushion 16(FIG. 1) placed thereon including the weight of persons or objectsplaced on top of the cushion 16 (FIG. 1) during use. The slats 50 of theillustrated spring system 24 can be selectively removed from the frame52 and reconfigured in different patterns as desired by a user. Forexample, the slats 50 in FIG. 4A are arranged in a first pattern, whilethe slats in FIG. 4B are arranged in a second pattern where additionalslats 50 have been added. A user may remove or add slats 50 to increaseor decrease the level of support or firmness provide by the springsystem 24.

FIG. 5B illustrates a close-up view of a portion of the spring system 24illustrated in FIG. 3A. FIG. 5B provides a close-up view of the firstend 58 of the slat 50 of the spring system 24. As illustrated in FIGS.5B and 6, the first end 58 may have a catch 130, such as a hooked end,which can provide for attachment of the slat 50 to the securing edge 102of the frame 52. In some embodiments, a side 132 of the catch 130 can bea planar surface so that it can fit flush against the walls or webs 98of the securing compartments 100. In another embodiment, the side 132 ofthe catch 130 may be rounded. In some embodiments, such as theembodiment shown in FIG. 5B, the catch 130 includes a retention groove134 configured to prevent the catch 130 from disengaging the securingedge 102. The retention groove 134 is complementary to the flange 114.The interface of the retention groove 134 and the flange can provide atrack for the catch 130 of the slat 50 to move along when the springsystem 24 is triggered, i.e., when a user sits on the cushion 16 (FIG.1). The retention grooves 134 prevents the slats 50 from becomingunhinged or moving out of the desired movement path during use. Theretention groove 134, either alone or in combination with the flange114, is an example of a retention member or a means for retaining theslat in contact with the frame. Other structures of the retention memberare possible, such as, but not limited to, other concave shapes, convexshape, projecting rims, collars that fits within a grooves, lockingstructures, such as pins, screws, plates, or the like, combinationstherefore or other structures to control or limit movement of a slatrelative to the frame. While the retention grooves 134 maintainengagement between the slats 50 and the frame 52, because the slats 50can be disengaged from the flanges 114, such as when the slats 50 loosestructure integrity, such that flexion is reduced, the slats 50 can beindividually replaced. This allows a user to repair and/or replaceindividual slats and reduces the need to replace the furniture as awhole.

When the spring system 24 is unloaded, the slats 50 may maintain a flatposition and sit in an even plane with the frame 52. When the slats 50are in a flat, unloaded position, the catch 130 may extend beyond thesecuring edge 102 such that the catch 130 may not come into contact withthe securing edge 102. When the spring system 24 is loaded or weighted,however, the slats 50 may bend or flex, positioning the center of theslat 52 below that of the frame 52. When loading occurs and the slats 50are flexed, the flexion of the slats 50 causes the distance between thefirst end 58 and the second end 60 of the slats 50 to shorten, therebycausing the catch 130 to tension on the securing edge 102 of the frame52. The flanges 114 engage with the retention grooves 134 allowing theflanges 114, and more generally the catch 130, to slide within the trackdefined by the flanges 114 and the walls or webs 98 of the securingcompartments 100.

The slats 50 can be made of any stiff material that can be flexed toaccommodate a weight load of up to 250 lbs, more preferably up to 300lbs, more preferably up to 350 lbs, more preferably up to 400 lbs, morepreferably up to 450 lbs, or more preferably up to 500 lbs. Forinstance, the slats 50 can be from a polymer, wood, metal, alloys,composites, fiberglass, carbon fiber, and combinations thereof, or thelike.

The slats 50 can flex in a bow-shape when loaded and return to aninitial flat or elongate shape when unloaded. In some embodiments, theslats 50 can include a graduating thickness, where the middle portion 62of the slat 50 is the thickest portion of the slat 50. The upper surface64 of the slat 50 where the cushion 16 can be placed can maintain acontinuous, flat surface, while the lower surface 66, or underside orbottom side, of the slat 50 can exhibit a curved shape to allow forgreater thickness in the middle portion 62. The greater thickness in themiddle portion 62 of the slats 50 may increase structural integrity ofthe slats 50 and prevent or slow wear by users of the furniture systemover time. Varying a thickness of the middle portion 62, and/or portionsof the slats 50 near the first end 58 and second end 68, can vary thebiasing force; areas of the slats 50 with greater thickness being moreresistant to bending and so the biasing force is greater than asituation where areas of the slats 50 are thinner. Additionally, varyinga composition of the material forming the frame 52, including the slat50, can also vary the biasing force.

Generally, the slats 50 can have a length ranging from about 10.0″ (10inches) to about 80.0″ (80 inches), from about 12.0″ to about 78″, andfrom about 14″ to about 75″. A thickness in the middle portion 62 canrange from about 0.060″ to 2.0″, from about 0.080″ to 1.0″, or fromabout 0.10″ to 0.9″. A thickness at one or both of the first end 58 andsecond end 68, closer to the middle portion than the catch 130, canrange from about 10% of the max thickness of the middle portion 62 ofthe slats 50, to about 70%, from about 20% to about 65%, or from about30% to about 60%. The slats 50 can have varying thicknesses along thelength of the slats 50. The varying thickness along the length canprovide reinforced support in certain locations along the slat, whileproviding for a greater range of flexibility at other locations alongthe length of the slats 50 as discussed herein.

In some embodiments where the slats 50 are made of metal, the thicknessof the slats 50 can be substantially less than the thicknesses recitedabove. For example, thickness of the middle portion 62 of a slat 50 madeof metal can range from about 0.00003″ to about 0.25″, from about0.0003″ to about 0.20″, or from about 0.003″ to about 0.15″.

Generally, the slats 50 have a general uniform width along their width,as illustrated in FIG. 4A. However, the slats 50 can have non-uniformwidths with a portion near the first end 58 and second end 60 beingnarrower than at the middle portion 62. Alternatively, a portion nearthe first end 58 and second end 60 can be wider than at the middleportion 62. By varying the widths, different flexion and biasing forcescan be generated by the slats 50.

FIGS. 7-9 illustrate views of another embodiment of a spring system 24 aaccording to the present invention. This discussion and disclosureassociated with spring system 24 is also applicable to the spring system24 a, and vice versa. Like structures are identified by like referencenumerals.

As illustrated, the spring system 24 a cooperates with a furniturecushion 16. The furniture cushion 16 can sit on top of the lid 22 of thespring system 24 a including a frame 52 a and a plurality of slats 50 a.The slats 50 a can have a catch 130 a at either one or both ends of theslats 50 a. The catch 130 a includes retention protrusions 140 a thatextends outwardly from the sides 132 a. The retention protrusions 140 aare secured within the walls or webs 98 a of the securing compartments100 a, and more particularly within slots 142 a, when the catch 130 a ispositioned within the securing compartment 100 a. While the retentionprotrusions 140 a maintain engagement between the slats 50 a and theframe 52 a, because the slats 50 a can be disengaged from the frame 52a, such as when the slats 50 lose structural integrity, such thatflexion is reduced, the slats 50 a can be individually replaced. Thisallows a user to repair and/or replace individual slats and reduces theneed to replace the furniture as a whole. The retention protrusions 140a, either alone or in combination with the slots 142 a, is anotherexample of a retention member or a means for retaining the slat incontact with the frame.

When the spring system 24 a is unloaded, as illustrated in FIGS. 8A and9A, the slats 50 a may maintain a flat position and sit in an even planewith the frame 52 a. When the slats 50 a are in a flat, unloadedposition, the catch 130 a may extend beyond the securing edge 102 a suchthat the catch 130 a may not come into contact with the securing edge102 a. When the spring system 24 a is loaded or weighted by a force orload L, however, the slats 50 a can bend or flex, positioning the centerof the slat 52 a below that of the frame 52 a. When loading occurs andthe slats 50 a are flexed, the flexion of the slats 50 a causes thedistance between the ends of the slats 50 a to shorten, thereby causingthe retention protrusions 140 a to move or track within the slots 142 aof the frame 52 a.

The slats 50 a can be made of any stiff material that can be flexed toaccommodate a weight load of up to 250 lbs, more preferably up to 300lbs, more preferably up to 350 lbs, more preferably up to 400 lbs, morepreferably up to 450 lbs, or more preferably up to 500 lbs. Forinstance, the slats 50 a can be from a polymer, wood, metal, alloys,composites, fiberglass, carbon fiber, and combinations thereof, or thelike.

The slats 50 a can flex in a bow-shape when loaded and return to aninitial flat or elongate shape when unloaded. In some embodiments, theslats can include a graduating thickness, where the middle portion 62 aof the slat 50 a is the thickest portion of the slat 50 a. The uppersurface 64 a of the slat 50 a where the cushion 16 (FIG. 1) can beplaced can maintain a continuous, flat surface, while the lower surface66 a, or underside or bottom side, of the slat 50 a can exhibit a curvedshape to allow for greater thickness in the middle portion 62 a. Thegreater thickness in the middle portion 62 a of the slats 50 a canincrease structural integrity of the slats 50 a and prevent or slow wearby users of the furniture system over time. Varying a thickness of themiddle portion 62 a, and/or portions of the slats 50 a near the firstend 58 a and second end 68 a, can vary the biasing force; areas of theslats 50 a with greater thickness being more resistant to bending and sothe biasing force is greater than a situation where areas of the slats50 a are thinner. Additionally, varying a composition of the materialforming the frame 52 a, including the slat 50 a, can also vary thebiasing force.

Generally, the slats 50 a can have a length ranging from about 10.0″ toabout 80.0″, from about 12.0″ to about 78″, and from about 14″ to about75″. A thickness in the middle portion 62 a can range from about 0.060″to 2.0″, from about 0.080″ to 1.0″, or from about 0.10″ to 0.9″. Athickness at one or both of the first end 58 a and second end 68 a,closer to the middle portion than the catch 130 a, can range from about10% of the max thickness of the middle portion 62 a of the slats 50 a,to about 70%, from about 20% to about 65%, or from about 30% to about60%. The slats 50 a can have varying thicknesses along the length of theslats 50 a. The varying thickness along the length may providereinforced support in certain locations along the slat, while providingfor a greater range of flexibility at other locations along the lengthof the slats 50 a as discussed herein.

In some embodiments where the slats 50 a are made of metal, thethickness of the slats 50 a can be substantially less than thethicknesses recited above. For example, thickness of the middle portion62 a of a slats 50 a made of metal can range from about 0.00003″ toabout 0.25″, from about 0.0003″ to about 0.20″, or from about 0.003″ toabout 0.15″.

Generally, the slats 50 a have a general uniform width along theirwidth, as illustrated in FIG. 7. However, the slats 50 a can havenon-uniform widths with a portion near the first end 58 a and second end60 a being narrower than at the middle portion 62 a. Alternatively, aportion near the first end 58 a and second end 60 a can be wider than atthe middle portion 62 a. By varying the widths, different flexion andbiasing forces can be generated by the slats 50 a.

FIGS. 10-12B illustrate another embodiment of a spring system 24 baccording to the present invention. This discussion and disclosureassociated with the spring systems 24 and 24 a are also applicable tothe spring system 24 b, and vice versa. Like structures are identifiedby like reference numerals.

FIGS. 10-12B illustrate a spring system 24 b including a furniturecushion 16. When assembled, the furniture cushion 16 can sit on top ofthe lid 22 b, which can include a frame 52 b and a plurality of slats 50b. The first end 58 b and second end 60 b of the slats 50 b can haveelongate openings 144 b through which a retention pin 146 b is insertedto attach the slats 50 b to the frame 52 b. The retention pin 146 b canbe formed with the frame 52 b, such that the retention pin 146 b andframe 52 b is a monolithic, one-piece structure. Alternatively, theretention pin 146 b can be attached to the frame 52, such as through athreaded engagement, friction fit engagement, interference fit, anadhesive bonding or coupling, combinations thereof, or other attachmentsmechanisms. The retention pin 146 b, either alone or in combination withthe elongate openings 144 b, is another example of a retention member ora means for retaining the slat in contact with the frame.

The first end 58 b and the second end 60 b of the slats 50 b includes acatch 130 b that is formed at right angles to a middle portion 62 b,although other angles less or greater than 90 degrees are possible. Thefirst end 58 b and the second end 60 b can extend towards the outside ofthe frame 52 b beyond a securing edge 102 b when the slats 50 b areunloaded or unweighted. The frame 52 b can include securing compartments100 b defined by walls or web 98 b. The securing compartments 100 b maybe of equal size and/or equal spacing. In other embodiments, thesecuring compartments 100 b can vary in size to accommodate differentsize slats and/or different slat patterns or configurations. While theretention pin 146 b maintains engagement between the slats 50 b and theframe 52 b, because the slats 50 b can be disengaged from the frame 52d, such as when the slats 50 d loose structure integrity, such thatflexion is reduced, the slats 50 d can be individually replaced. Thisallows a user to repair and/or replace individual slats and reduces theneed to replace the furniture as a whole.

Loading on the spring system 24 b with a force or load L, as illustratedin FIGS. 11B and 12B, causes the slats 50 b to flex in a downward motionso that the middle portion 62 b of the slats 50 b is below the frame 52b. When the slats 50 b are loaded and flexed, the elongate openings 144b allow the slats 50 b, which have been secured by retention pin 146 binserted through the elongate openings 144 b, to slide against the frame52 b and flex without becoming unhinged from the frame 52 b as thecatches 130 b are tensions against the securing edges 102 b. The firstend 58 b and the second end 60 b of the slats 50 b can catch on thesecuring edge 102 b to limit flexion and support weight applied to thespring system 50 b. The first end 58 b and the second end 60 b of theslats 50 b can be flush with the securing edge 102 b when the slats 50 bare flexed. When the slats 50 b are unloaded or unweighted, asillustrated in FIGS. 11A and 12A, the first end 58 b and the second end60 b of the slats 50 b extend beyond the securing edge 102 b. Whenunloaded or unweighted, the slats 50 b are preferably level with theupper surface 64 b of the frame 52 b.

As with the other embodiments, the slats 50 b can be made of any stiffmaterial that can be flexed to accommodate a weight load of up to 250lbs, more preferably up to 300 lbs, more preferably up to 350 lbs, morepreferably up to 400 lbs, more preferably up to 450 lbs, or morepreferably up to 500 lbs. For instance, the slats 50 b can be from apolymer, wood, metal, alloys, composites, fiberglass, carbon fiber, andcombinations thereof, or the like.

The slats 50 b can flex in a bow-shape when loaded and return to aninitial flat or elongate shape when unloaded. In some embodiments, theslats can include a graduating thickness, where the middle portion 62 bof the slat 50 b is the thickest portion of the slat 50 b. The uppersurface 64 b of the slat 50 b where the cushion 16 (FIG. 1) can beplaced can maintain a continuous, flat surface, while the lower surface66 b, or underside or bottom side, of the slat 50 b can exhibit a curvedshape to allow for greater thickness in the middle portion 62 b. Thegreater thickness in the middle portion 62 b of the slats 50 b canincrease structural integrity of the slats 50 b and prevent or slow wearby users of the furniture system over time. Varying a thickness of themiddle portion 62, and/or portions of the slats 50 near the first end 58and second end 68, can vary the biasing force; areas of the slats 50with greater thickness being more resistant to bending and so thebiasing force is greater than a situation where areas of the slats 50are thinner. Additionally, varying a composition of the material formingthe frame 52, including the slat 50, can also vary the biasing force.

Generally, the slats 50 b can have a length ranging from about 10.0″ toabout 80.0″, from about 12.0″ to about 78″, and from about 14″ to about75″. A thickness in the middle portion 62 b can range from about 0.060″to 2.0″, from about 0.080″ to 1.0″, or from about 0.10″ to 0.9″. Athickness at one or both of the first end 58 b and second end 68 b,closer to the middle portion than the catch 130 b, can range from about10% of the max thickness of the middle portion 62 b of the slats 50 b,to about 70%, from about 20% to about 65%, or from about 30% to about60%. The slats 50 b can have varying thicknesses along the length of theslats 50 b. The varying thickness along the length may providereinforced support in certain locations along the slat, while providingfor a greater range of flexibility at other locations along the lengthof the slats 50 b as discussed herein.

In some embodiments where the slats 50 b are made of metal, thethickness of the slats 50 b may be substantially less than thethicknesses recited above. For example, thickness of the middle portion62 b of a slats 50 b made of metal can range from about 0.00003″ toabout 0.25″, from about 0.0003″ to about 0.20″, or from about 0.003″ toabout 0.15″.

Generally, the slats 50 b have a general uniform width along theirwidth, as illustrated in FIG. 10. However, the slats 50 b can havenon-uniform widths with a portion near the first end 58 b and second end60 b being narrower than at the middle portion 62 b. Alternatively, aportion near the first end 58 b and second end 60 b can be wider than atthe middle portion 62 b. By varying the widths, different flexion andbiasing forces can be generated by the slats 50 b.

FIGS. 13-15B illustrate another embodiment of a spring system 24 caccording to the present invention. This discussion and disclosureassociated with the spring systems 24, 24 a, 24 b are also applicable tothe spring system 24 c, and vice versa. Like structures are identifiedby like reference numerals.

FIG. 13-15B illustrate a spring system 24 c including a furniturecushion 16. The spring system 26 c may include a lid 22 c comprising aframe 52 c, a plurality of slats 50 c, and one or more retention plates150 c. The slats 50 c may be positioned on the frame 52 c so that thefirst end 58 c and second end 60 c of the slats 50 c are positioned insecuring compartments 100 c on the frame 52 c. A retention plate 150 cmay be applied over the first end 58 c and second end 60 c of the slats50 c and secured onto the frame 52 c, such as by fasteners, screws,pins, nuts and bolts, or other releasable fastener, so that the slats 50c are sandwiched between the frame 52 c and the plate 150 c. While theplates 150 c maintain engagement between the slats 50 c and the frame 52c, because the slats 50 c can be disengaged from the frame 52 c byremoving the plates 150 c, such as when the slats 50 c lose structuralintegrity, such that flexion is reduced, the slats 50 c can beindividually replaced. This allows a user to repair and/or replaceindividual slats and reduces the need to replace the furniture as awhole. The retention plate 150 c, either alone or in combination withfasteners, is another example of a retention member or a means forretaining the slat in contact with the frame.

When the spring system 24 c is unweighted, as illustrated in FIGS. 14Aand 15A, the upper surface 64 c of the slats 50 c sits level with theframe 52 c and the first end 58 c and second end 60 c extend beyond thesecuring edge 102 c into the securing compartment 100 c on the frame 52c. The retention plate 150 c may be secured over the top of the firstend 58 c and second end 60 c of the slats 50 c. When the spring system24 c is loaded or weighted with a force or load L, as illustrated inFIGS. 14B and 15B, the slats 50 c will flex. The middle portion 62 c ofthe slats 50 c may flex below the height of the frame 52 c and the firstend 58 c and second end 60 c may tension against the securing edge 102c. The first end 58 c and second end 60 c of the slats 50 c may besecured in place by the retention plates 150 c in a configuration thatallows the slats 50 c to slide and flex without detaching from the frame52 c.

As with the other embodiments, the slats 50 c may be made of any stiffmaterial that can be flexed to accommodate a weight load of up to 250lbs, more preferably up to 300 lbs, more preferably up to 350 lbs, morepreferably up to 400 lbs, more preferably up to 450 lbs, or morepreferably up to 500 lbs. For instance, the slats 50 c can be from apolymer, wood, metal, alloys, composites, fiberglass, carbon fiber, andcombinations thereof, or the like.

The slats 50 c may flex in a bow-shape when loaded and return to aninitial flat or elongate shape when unloaded. In some embodiments, theslats may include a graduating thickness, where the middle portion 62 cof the slat 50 c is the thickest portion of the slat 50 c. The uppersurface 64 c of the slat 50 c where the cushion 16 (FIG. 1) may beplaced may maintain a continuous, flat surface, while the lower surface66 c, or underside or bottom side, of the slat 50 c may exhibit a curvedshape to allow for greater thickness in the middle portion 62 c. Thegreater thickness in the middle portion 62 c of the slats 50 c mayincrease structural integrity of the slats 50 c and prevent or slow wearby users of the furniture system over time. Varying a thickness of themiddle portion 62, and/or portions of the slats 50 near the first end 58and second end 68, can vary the biasing force; areas of the slats 50with greater thickness being more resistant to bending and so thebiasing force is greater than a situation where areas of the slats 50are thinner. Additionally, varying a composition of the material formingthe frame 52, including the slat 50, can also vary the biasing force.

Generally, the slats 50 c can have a length ranging from about 10.0″ toabout 80.0″, from about 12.0″ to about 78″, and from about 14″ to about75″. A thickness in the middle portion 62 c can range from about 0.060″to 2.0″, from about 0.080″ to 1.0″, or from about 0.10″ to 0.9″. Athickness at one or both of the first end 58 c and second end 68 c,closer to the middle portion than the catch 130 c, can range from about10% of the max thickness of the middle portion 62 c of the slats 50 c,to about 70%, from about 20% to about 65%, or from about 30% to about60%. The slats 50 c can have varying thicknesses along the length of theslats 50 c. The varying thickness along the length may providereinforced support in certain locations along the slat, while providingfor a greater range of flexibility at other locations along the lengthof the slats 50 c as discussed herein.

In some embodiments where the slats 50 c are made of metal, thethickness of the slats 50 c may be substantially less than thethicknesses recited above. For example, thickness of the middle portion62 c of a slats 50 c made of metal can range from about 0.00003″ toabout 0.25″, from about 0.0003″ to about 0.20″, or from about 0.003″ toabout 0.15″.

Generally, the slats 50 have a general uniform width along their width,as illustrated in FIG. 13. However, the slats 50 c can have non-uniformwidths with a portion near the first end 58 c and second end 60 c beingnarrower than at the middle portion 62 c. Alternatively, a portion nearthe first end 58 c and second end 60 c can be wider than at the middleportion 62 c. By varying the widths, different flexion and biasingforces can be generated by the slats 50 c.

FIGS. 16-18B illustrate another embodiment of a spring system 24 daccording to the present invention. This discussion and disclosureassociated with the spring systems 24, 24 a, 24 b, 24 c are alsoapplicable to the spring system 24 d, and vice versa. Like structuresare identified by like reference numerals.

FIGS. 16-18B illustrate another embodiment of a spring system 24 dincluding a furniture cushion 16. The spring system 24 d may include alid 22 d having a frame 52 d and a plurality of slats 50 d. The firstend 58 d and second end 60 d of the slats 50 d may have elongateopenings 152 d through which retention fasteners 154 d may be insertedand secured into retention bores 156 d on the frame 52 d. The retentionbores 156 d may be raised, or project or extend upward from the frame 52d. The retention fasteners 154 d may comprise screws, pins, or the like.While the retention fasteners 154 d maintain engagement between theslats 50 d and the frame 52 d, because the slats 50 can be disengagedfrom the frame 52 d, such as when the slats 50 d loose structureintegrity, such that flexion is reduced, the slats 50 d can beindividually replaced. This allows a user to repair and/or replaceindividual slats and reduces the need to replace the furniture as awhole. The retention fasteners 154 d, either alone or in combinationwith retentions bores 156 d and the elongate openings 152 d, is anotherexample of a retention member or a means for retaining the slat incontact with the frame.

When the spring system 24 d is unloaded or unweighted, as illustrated inFIGS. 17A and 18B, the slats 50 d may sit level with the frame 52 d. Thefirst end 58 d and second end 60 d of the slats 50 d may extend past theretention bore 156 d to the edge of the frame 52 d. In contrast, when aweight or load L is applied downwardly on the spring system 24 d, asillustrated in FIGS. 17B and 18B, the slats 50 d slide and flex at amiddle portion or point 62 d. In order to flex, the elongate openings152 d allow the slats 50 d to slide along a desired track dictated bythe length 158 d of the elongate opening 152 d, and flex until theretention fastener 156 d reaches a terminal end of the elongate opening152 d. That is, the slats 50 d slide along the length 158 d of theelongate openings 152 d when flexed, and flexion may reach a terminalpoint when the retention fastener 154 d reaches an end of the elongateopening 152 d. When the spring system 24 d is weighted or loaded, as inFIG. 18B, the slats 50 d may flex or bend below the height of the frame52 d.

As with the other embodiments, the slats 50 d may be made of any stiffmaterial that can be flexed to accommodate a weight load of up to 250lbs, more preferably up to 300 lbs, more preferably up to 350 lbs, morepreferably up to 400 lbs, more preferably up to 450 lbs, or morepreferably up to 500 lbs. For instance, the slats 50 d can be from apolymer, wood, metal, alloys, composites, fiberglass, carbon fiber, andcombinations thereof, or the like.

The slats 50 d may flex in a bow-shape when loaded and return to aninitial flat or elongate shape when unloaded. In some embodiments, theslats may include a graduating thickness, where the middle portion 62 dof the slat 50 d is the thickest portion of the slat 50 d. The uppersurface 64 d of the slat 50 d where the cushion 16 (FIG. 1) may beplaced may maintain a continuous, flat surface, while the lower surface66 d, or underside or bottom side, of the slat 50 d may exhibit a curvedshape to allow for greater thickness in the middle portion 62 d. Thegreater thickness in the middle portion 62 d of the slats 50 d mayincrease structural integrity of the slats 50 d and prevent or slow wearby users of the furniture system over time. Varying a thickness of themiddle portion 62 d, and/or portions of the slats 50 d near the firstend 58 d and second end 68 d, can vary the biasing force; areas of theslats 50 d with greater thickness being more resistant to bending and sothe biasing force is greater than a situation where areas of the slats50 d are thinner. Additionally, varying a composition of the materialforming the frame 52 d, including the slat 50 d, can also vary thebiasing force.

Generally, the slats 50 d can have a length ranging from about 10.0″ toabout 80.0″, from about 12.0″ to about 78″, and from about 14″ to about75″. A thickness in the middle portion 62 d can range from about 0.060″to 2.0″, from about 0.080″ to 1.0″, or from about 0.10″ to 0.9″. Athickness at one or both of the first end 58 d and second end 68 d,closer to the middle portion than the catch 130 d, can range from about10% of the max thickness of the middle portion 62 d of the slats 50 d,to about 70%, from about 20% to about 65%, or from about 30% to about60%. The slats 50 d can have varying thicknesses along the length of theslats 50 d. The varying thickness along the length may providereinforced support in certain locations along the slat, while providingfor a greater range of flexibility at other locations along the lengthof the slats 50 d as discussed herein.

In some embodiments where the slats 50 d are made of metal, thethickness of the slats 50 d may be substantially less than thethicknesses recited above. For example, thickness of the middle portion62 d of a slats 50 d made of metal can range from about 0.00003″ toabout 0.25″, from about 0.0003″ to about 0.20″, or from about 0.003″ toabout 0.15″.

Generally, the slats 50 d have a general uniform width along theirwidth, as illustrated in FIG. 16. However, the slats 50 d can havenon-uniform widths with a portion near the first end 58 d and second end60 d being narrower than at the middle portion 62 d. Alternatively, aportion near the first end 58 d and second end 60 d can be wider than atthe middle portion 62 d. By varying the widths, different flexion andbiasing forces can be generated by the slats 50 d.

FIGS. 3A-18 illustrate various retention members or means for retainingthe slat in contact with the frame. It will be understood by one skilledin the art that the spring systems, and more generally, the furnitureitems, contemplated by this application can include one or more of theretention members of FIGS. 3A-18, whether used alone or in combinationwith one another. For instance, the spring systems, and more generally,the furniture items, contemplated by this application, can include anycombination of the retentions members described herein, such that eachretention member described herein can be used in combination with one ormore of the other retentions members described herein.

FIG. 19-21B illustrate another embodiment of a spring system 24 eaccording to the present invention. This discussion and disclosureassociated with the spring systems 24, 24 a, 24 b, 24 c, 24 d are alsoapplicable to the spring system 24 e, and vice versa. Like structuresare identified by like reference numerals.

In the embodiment of FIGS. 19-21B, a spring system 24 e may be formed asa single piece, such as a monolithic structure. FIGS. 19-21B show thespring system 24 e and a furniture cushion 16. When assembled, thefurniture cushion 16 may rest on top of the spring system 24 e. Thespring system 24 e may include a lid 22 e comprising a frame 52 e with aplurality of slats 50 e molded onto the frame 52 e. The slats 50 e maybe formed in a bow shape so that in an unweighted position, asillustrated in FIGS. 20A and 21A, a middle portion 62 e of the slats 50e is positioned higher relative to a first end 58 e and a second end 60e of the slats 50 e. The slats 50 e may be configured in a raised orbow-shape, perpendicular to the edges of the frame 52 e. The pre-formedbow-shape of the slats 50 e may provide a mechanism for the slats 52 eto return to an initial position after they are flexed and/or a load isapplied. When the spring system 24 e is flexed and/or a load L isapplied downward on the spring system 24 e, as in FIGS. 20B and 21B, themiddle portions 62 e of the slats 50 e flex downwardly under load whilethe first end 58 e and the second end 60 e of the slats 50 e remain atthe same height as the frame 52 e.

The slats 50 e are formed with the frame 52 e via the first end 58 e andthe second end 60 e of the slats 50 e. The first end 58 e and the secondend 60 e are form with an interior support 86 e of the frame 52 e. Theslats 50 e form a bow-shape, with a center or mid-point 158 e, or apexof the slats 50 e is level with a top surface of the frame 52 e. Theslats 50 e may have a mid-point 158 e level or even with the height ofthe frame 52 e to allow the furniture cushion 16 to sit comfortably orflat on top of the spring system 24 e when the system is unloaded. Whena load is applied downward on the spring system 24 e, as illustrated inFIGS. 20B and 21B, the mid-point 158 e of the slats 50 e may extendbelow the frame 52 e. The slats 50 e may be thicker towards the firstend 58 e and the second end 60 e. These thicker ends serve asstabilizing sections 160 e that provide a biasing force to return theslats 50 e to an initial position after the spring system 24 e isunloaded. Varying a thickness of the stabilizing sections 160 e can varythe biasing force; slats 50 e with thicker stabilizing sections 160 ebeing more resistant to bending and so the biasing force is greater thana situation where the stabilizing sections 160 e are thinner.Additionally, varying a composition of the material forming the frame 52e, including the slat 50 e and the stabilizing sections 160 e, can alsovary the biasing force.

As with the other embodiments, the slats 50 e may be made of any stiffmaterial that can be flexed to accommodate a weight load of up to 250lbs, more preferably up to 300 lbs, more preferably up to 350 lbs, morepreferably up to 400 lbs, more preferably up to 450 lbs, or morepreferably up to 500 lbs. For instance, the slats 50 e can be from apolymer, wood, metal, alloys, composites, fiberglass, carbon fiber, andcombinations thereof, or the like.

Generally, the slats 50 e can have a length ranging from about 10.0″ toabout 80.0″, from about 12.0″ to about 78″, and from about 14″ to about75″. A thickness at one or both of the first end 58 e and second end 68e, closer to the middle portion than the catch 130 e, can range fromabout 0.060″ to 2.0″, from about 0.080″ to 1.0″, or from about 0.10″ to0.9″. A thickness in the middle portion 62 e can range from about 10% ofthe max thickness of the thickness at one or both of the first end 58 eand the second end 68 e of the slats 50, to about 70%, from about 20% toabout 65%, or from about 30% to about 60%. The slats 50 e can havevarying thicknesses along the length of the slats 50 e. The varyingthickness along the length may provide reinforced support in certainlocations along the slat, while providing for a greater range offlexibility at other locations along the length of the slats 50 e asdiscussed herein.

In some embodiments where the slats 50 are made of metal, the thicknessof the slats 50 may be substantially less than the thicknesses recitedabove. For example, thickness of the middle portion 62 and or thicknessof one or both of the first end 58 e and the second send 68 e of slats50 made of metal can range from about 0.00003″ to about 0.25″, fromabout 0.0003″ to about 0.20″, or from about 0.003″ to about 0.15″.

Generally, the slats 50 e have a general uniform width along theirwidth, as illustrated in FIG. 19. However, the slats 50 e can havenon-uniform widths with a portion near the first end 58 e and second end60 e being narrower than at the middle portion 62 e. Alternatively, aportion near the first end 58 e and second end 60 e can be wider than atthe middle portion 62 e. By varying the widths, different flexion andbiasing forces can be generated by the slats 50 e.

In some embodiments, the frame and spring system described herein can beformed onto, or fixedly attached to a furniture base. In someembodiments, the spring system may be formed onto or fixedly attached toa furniture base without the use of a frame. In another embodiment, theframe may be formed onto or fixedly attached on all sides to a furniturebase, wherein the frame may provide attachment points to which slats maybe selectively attached and arranged in any manner described above. Inthese embodiments, the spring system and/or frame may not be removablefrom the furniture base. Similarly, the frame and/or spring system maynot be moved to allow for storage within the furniture base. Rather,this configuration may only provide support for a user's weight appliedto the furniture.

In some embodiments, the lid and spring system described herein can beintegrated into a cushion. FIG. 22A illustrates an exploded view of anembodiment of an integrated lid-cushion assembly 200 including a springsystem 224 and a cushion 216. While reference is made to the springsystem 224, it will be understood that any of the embodiments orconfigurations of lids and spring systems described herein can beintegrated into the cushions. The spring system 224 may be set inside abottom side 230 of a cushion 216. In an embodiment, the cushion 216 hasa fill member 232 covered by a liner 234. The liner 234 can be a fabricmaterial that is either water permeable or impermeable. An advantage ofa water impermeable liner is that the liner will help protect theinterior contents of the cushion 216. The fill member 232 can be a pieceof foam, combinations of layers of foam of differing densities, memoryfoam, polyurethane foam, feathers and down, polyester, batting, andcombinations thereof or other materials.

The bottom side 230 of the cushion 216 can include a flap 236 orselectively openable portion of the liner 234. The edges or corners ofthe spring system 224 may be secured within pockets 238 on an interiorside of the liner 234 on the bottom side 230 of a cushion 216. Statedanother way, the pockets 238 are formed between the fill member 232 andthe liner 234 and can receive the spring system 224.

Once the spring system 224 is positioned into the pocket 238 of thecushion 216, the flap 236 may cover and secure the spring system 224inside the cushion 216, as shown in FIG. 22B. The flap 236 may bedetachably coupled through the use of a removable securing mechanism,such as a hook and pile mechanism, e.g. VELCRO®, one or more zippers,male and female snap members, hook and latch type fasteners, or anyother type of securing means that will facilitate the flap 236 beingselectively removable. The spring system 224 may be transferable betweencompatible furniture components, for example, the consumer may want tochange the appearance of the furniture by changing the removeable linerof the cushions or may want to transition between different furnitureconfigurations. In some embodiments, extendable slats may beincorporated to allow a furniture section to be extended to form alounger.

The spring system of the present disclosure may be utilized in varioustypes of modular furniture, including part of a bed system or modularbed system. The modular system advantageously simplifiesmanufacturability, durability through flipping, relocating & replacingworn modules, and simplifies packing/shipping. The modular bed systemallows modular components to be used to resize a bed overtime. Forinstance, the modular components forming a twin bed can be utilized toform Full, Queen, King, and California King beds by adding other modularcomponents.

With reference to FIGS. 23A-23B, illustrated is a modular component 310of a bed system 300; the modular component 310 being combined with othersimilarly sized or differently sized modular components 310 to form abed. The modular component 310 utilizes a modular mattress 316 that canbe selectively attached to a support structure 312 with a spring system324. The modular mattress 316 can be similar to the cushions describedherein, the support structure 312 can be similar to the bases describedherein, and the spring system 324 can be similar to the other springsystems described herein. As such, the disclosures and discussions ofthe cushions, bases, and spring systems described herein are alsoapplicable to the support structure 312, the modular mattress 316, andthe spring system 324. Like structures, therefore, are identified withlike reference numerals.

The modular components 310 may be detachably coupled through the use ofsecuring mechanisms 342 (FIG. 23B) on the opposing sides of the modularcomponents 310. For instance, the securing mechanism 342 can be a hookand loop mechanism, e.g. VELCRO®, one or more zippers, male and femalesnap members, magnets, hook and latch type fasteners, mechanicalinterlocks or any other type of securing means that will facilitate themodular components 310 being selectively coupled to one another.Alternatively, a bed frame (e.g., a rigid bed frame) may be used tosecure a plurality of modular components 310 in a desired configurationto form a completed bed system 300.

The modular mattress 316 can include materials such as foam,polyurethane, memory foam, pocket coils, Durafoam, high-density foam,and other materials used in mattress construction. In some embodiments,the modular mattress 316 may be a dual-comfort module, where a firstside of the modular mattress 316 provides soft or light support, and asecond side provides medium or firm support. The consumer may turn themodular mattress 316 so that the preferred side of the dual-comfortmodule is facing up to form the sleeping surface. The advantage of thisfeature is that the consumer may adjust the support level of themattress as often as they might prefer.

In some embodiments, the spring system 324 may be incorporated into theinterior of a modular mattress 316 or mattress module 310. For example,mattress materials such as foam can be molded on to and cover the springsystem 324 on all surfaces so that the spring system 324 is fixed insideof a mattress module 310.

Individual component modules 310 and/or the bed system 300 as a whole,can include removable toppers 340 (FIG. 23A) formed of down, memoryfoam, etc. to provide comfort and durability. These removeable toppers340 may be added to provide an additional degree of support andcustomization to the modular components 310. The removeable toppers 340may also provide continuity between mattress modules 316 and preventsplitting or sinking between mattress modules 316.

As mentioned above, the modular components 310 forming a twin bed can beutilized to form Full, Queen, King, and California King beds by addingother modular components. Some embodiments utilize modular components310 complying with an equation:y=2xwhere, x is the component width (W) and y is the component length (L).

In the bed system 300 a of FIG. 24, the width of modular component 310Ais 12.5 inches and the length of the modular component 310A is 25.0inches. This allows a majority of the bed area of the bed system 300 auses the modular component 310A of one size. The twin bed can beincreased in size to the Full bed by adding a number of modularcomponents 310A. To form the Queen, King, and California King sizedbeds, one or more modular components 310B and/or module components 310Aand 310B can be added to form the bed system 300 a. The modularcomponent 310B can have a width of 5 inches and a length of 75 inches.

The modular components 310A and 310B, with associated support structure,mattress modules, and spring systems, may be manufactured in a number ofsizes to allow a user to incrementally add components to create aparticular bed size. For example, and as illustrated in FIGS. 24-28,modular components 310A, 310B, and 310C can have various other sizes andbe combined in a variety of different orientations. Table 1 belowprovides some possible sizes of the modular components 310A, 310B, 310C,310D, 310E, and 310F for the bed systems 300 a, 300 b, 300 c, 300 d, and300 e. It will be understood that the sizes referenced in Table 1 canapply to the modular component as a whole, and each of the modularmattress 316 and support structure 312 associated with the modularcomponent 300. Additionally, the spring system 324 can have similarsizes to those described in Table 1, while accommodating for restingupon the support structure 312 in a similar way that the spring systemsrest on the bases described herein.

TABLE 1 Module A Module B Module C Module D Module E Module F (L × W) (L× W) (L × W) (L × W) (L × W) (L × W) FIG. 24  25″ × 12.5″ 75″ × 5″ — — —— FIG. 25 25″ × 39″  25″ × 16″ 25″ × 5″ 5″ × 60″ 5″ × 78″ 5″ × 71″ FIG.26 25″ × 30″ 75″ × 4″  25″ × 25″ 5″ × 60″ 5″ × 38″ 5″ × 33″ FIG. 27 75″× 13″ 75″ × 4″ — — — — FIG. 28 40″ × 13″  35″ × 13″ 40″ × 4″ — — —

The modular combinations described above are non-limiting examples ofmodular component combinations which may be utilized to create the bedsystems. As such, a modular component can have a length from about 4.0″to about 85.0″, from about 4.5″ to about 78.0″, from about 5.0″ to about75.0″, from about 5.5″ to about 72.5″, or from about 6.0″ to about70.0″. The modular component can have a width from about 3.0″ to about85.0″, from about 3.5″ to about 78.5″, from about 4.0″ to about 75.0″,from about 4.5″ to about 72.5″, or from about 5.0″ to about 70.0″.

The number and size of the modular components 310 used may be dependenton the comfort and support preferences of a user. For example, a userrequiring more variation in support (i.e. firm support, soft support,etc.) may prefer a configuration utilizing modular components 310 inorder to increase/decrease the degree of support for different areas ofthe user's body. In such a case, the modular component 310 near theuser's hips might have firmer support than the modular components 310near the user's head or feet. Alternatively, the modular component 310near the user's hips might have softer support than the modularcomponents 310 near the user's head or feet. Each modular component 310used in a particular bed system 300 can have the same or differentsupport properties. Where two or more persons share the same bed system300, each user may customize their portion of the bed system 300 totheir support preference. This feature may also be beneficial in placeslike hotels, guest rooms, and other short-term use situations where theuser of the mattress module might change frequently and may prefer adifferent degree of comfort and support relative to other uses.

In addition to changing the particular modular component 310, and any ofthe mattress module 316 and the spring system 324, a density of modularcomponents 310 can also vary to change the support properties. Forinstance, for selective support a higher number of modular components310 can be used to form the bed area. Conversely, a user who prefersuniform support may prefer a bed system 300 having fewer modularcomponents 300 which may simplify and/or decrease the degree ofvariation.

In some embodiments, the modular components described above may, incertain combinations, require that a casing be applied to achieve thecorrect mattress size. The casing may be sized and shaped to compensatefor missing length and/or width and/or depth needed to form a standardsize mattress. For example, in one embodiment shown in FIGS. 32A-32B, atwin XL-size casing 600 may be applied to add about 5.0″ of length toseveral mattress modules A (310 a) forming a twin-size mattress in orderto convert the twin-size mattress into a twin XL size mattress. Thecasing 600 in FIG. 32A is shown having an upper section 601 and a lowersection 602 joined by a connector 603. The connector 603 shown is azipper, though buttons, snaps, clips, magnets, or the like can be used.The casing 600 is configured to contain the mattress modules 310 aplaced therein. In some embodiments, the lower section 602 of the casing600 includes opposing sides 606 extending upwards from a bottom surface607, with corners 608 formed therebetween. The components include thelower section 602 can be formed from a single piece of material. In someembodiments, it may be advantageous for the corners 608 to be fittedcorners, or corners with extra elastic properties relative to the restof the casing 600 so that the corners may be stretched and tightlysecured around the mattress modules 310 a to provide an increased degreeof support to the fully formed mattress.

In one embodiment, in order to form a mattress, mattress modules 310 aare configured inside of the casing 600. The upper section 601 of thecasing 600 is then joined to the lower section 602 of the casing 600 viathe connector 603 in order to close the casing. In the embodiment shownin FIG. 32B, the upper section 601 is disconnected from the lowersection 602 on three sides, forming a flap 605, providing access to theinterior of the lower section 602 of the casing 600. In someembodiments, the upper section 601 can be completely removed from thelower section 602 when the casing 600 is opened to place mattressmodules 310 a inside, and then rejoined to form a closed, completedmattress. In some embodiments, the upper section 601 and lower section602 can be equally sized, by having the connector 603 positioned at amidpoint of the opposing sides 606 and extending latitudinally aroundthe casing 600.

In some embodiments, the flap 605 can also function as a mattress topperand can be formed of down, memory foam, etc. to provide an additionaldegree of customization and support to the mattress modules 310 a. Whenthe flap 605 or the upper section 601 of the casing 600 functions as atopper, it can also provide continuity between mattress modules 310 aand prevent splitting or sinking between modules.

An extender 604 is fixed within the interior of the lower portion 602 ofthe casing 600. In some embodiments, the extender portion 604 can beselectively removeable and/or repositionable within the casing 600. Incasing 600, the extender 604 is positioned at an end of the casing 600in order to extend the length of the mattress formed by the mattressmodules 310 a. In some embodiments, the extender 604 may be used toexpand the width of the mattress. The extender 604 can be made ofmaterials generally used in mattress construction such as foam, foamalternatives, polyester blends, quilting, padding, gel, and othersimilarly resilient materials. The extender 604 must be stiff enough tosupport a user and not collapse under weight, while providing acomfortable surface. The mattress modules 310 a can be placed side byside within the casing 600, and are preferably flush with each other andthe extender 604 so as to avoid gaps in the completed mattress.

FIGS. 33A and 33B illustrate an alternative embodiment of a casing 700as applied to a number of mattress modules 310 a to form, for example, afull-size mattress. The casing 700 can have elastic properties, and assuch, can be applied to a number of mattress modules 310 a by securingthe casing 700 over a corner 704 and then stretching the casing 700 overthe remaining mattress modules 310 a. The casing 700 may includeextenders 702, fixed within the casing 700 to extend the length and/orwidth and/or depth of the mattress modules to form a standard sizemattress. Similar to the extender 604, extender 702 can be made ofmaterials generally used in mattress construction and must be stiffenough to support the weight of a user without collapsing, yet provide acomfortable surface similar to a mattress surface. A retention band 703on the peripheral edge of the casing 700 can be used to selectivelysecure the casing 700 over a number of mattress modules 310 a. Theretention band 703 as shown in FIG. 33C is constructed of elasticmaterial. In another embodiment, the retention band 703 can comprisebuttons, snaps, clips, pins, hook and loop fasteners, magnets, or thelike.

The casing for a twin-size mattress can add a width at least from about0.5″, from about 1.0″, or from about 1.5″. For example, a twin-sizecasing may add a width from about 0.5″ to about 2.0″, or from about 1.0″to about 1.75″. A casing for a twin XL size mattress may add onlylength, while some twin XL casings may add both length and width toseveral modules forming a mattress. As such, a casing for a twin XL sizemattress may add at least about 3.0″ in length, at least about 4.0″ inlength, or at least about 5.0″ in length. For example, a twin XL casingmay add a length of about 3.0″ to about 6.0″, about 3.5″ to about 5.5″,or about 4.0″ to about 5.0″. A casing for a twin XL may also add thewidth for a twin-size mattress as recited above.

A casing for a full-size mattress can add a width from at least 0.5″,from about 1.0″, or from about 1.5″. For example, a full-size casing mayadd a width from about 0.5″ to about 3.0″, or from about 1.0″ to about2.5″. A casing for a full XL size mattress may add only length, whilesome full XL casings may add both length and width to several modulesforming a mattress. As such, a casing for a full XL size mattress mayadd at least about 3.0″ in length, at least about 4.0″ in length, or atleast about 5.0″ in length. For example, a full XL casing may add alength of about 3.0″ to about 6.0″, about 3.5″ to about 5.5″, or about4.0″ to about 5.0″. A casing for a full XL may also add the width for afull-size mattress as recited above.

A casing for a queen size mattress can add a length from at least about3.0″, about 4.0″, or about 5.0″. For example, a queen size casing mayadd a length from about 3.0″ to about 7.0″, from about 4.0″ to about6.5″, or from about 4.5″ to about 6.0″. A casing for a king sizemattress can add a length and/or width to several mattress modulescombined to form a king size bed. A king size mattress casing can add alength from at least about 3.0″, about 4.0″, or about 5.0″. For example,a king size casing may add a length from about 3.0″ to about 7.0″, fromabout 4.0″ to about 6.5″, or from about 4.5″ to about 6.0″. A king sizecasing can add a width from at least about 1.0″, about 2.0″, or about3.0″. For example, a king size casing may add a width from about 1.0″ toabout 4.0″, from about 2.0″ to about 3.5″, or from about 3.0″ to about4.0″.

A casing for a California king size mattress can add a length to severalmattress modules combined to form a California king size bed. ACalifornia king size mattress casing can add a length from at leastabout 7.0″, about 8.0″, or about 9.0″. For example, a California kingsize casing may add a length from about 7.0″ to about 12.0″, from about8.0″ to about 11.00″, or from about 9.0″ to about 10.0″.

The casing may be formed of materials used in mattress construction suchas foam, polyurethane, memory foam, pocket coils, Durafoam, high-densityfoam, or the like. Some casings may be a rigid casing in order tosupport the weight of a user without collapsing.

Turning now to FIG. 29, the spring system 424 of a bed system 400 inanother configuration is illustrated. The disclosure of bed system 300and associated spring system 324 is also applicable to thisconfiguration, and vice versa.

As depicted the spring system 424 includes a frame 452 and slats 450.The frame 452 is illustrated supported by a plurality of supportstructure 412, such as a base described herein. The slats 450 canattached to the frame 452 through the connections described earlier,such as catches and securing edges, retentions pins and elongateopenings, projections and slots, plates, elongate openings andfasteners, being integrally formed as a monolithic one-piece structure,combinations therefore, or the like.

To accommodate for changing a size of the bed system 400, such as when aconsumer may initially configure a twin-size bed for a child and as thechild grows the bed system 400 is extended to the width of a full-sizebed, the frame 452 can be replaced with a larger size and the slats 450telescope to extend to the larger size. As illustrated in FIG. 29, theslats 450 include a first slat portion 454 a and a second slat portion454 b. The slat portions 454 a and 454 a slide relative to each other,with the first slat portion 454 a being received within a portion of thesecond slat portion 454 b. The first slat portion 454 a includes abiased locking pin 480 that can be received within a complementaryopening 482 in the second slat portion 454 b. As the biasing force ofthe biased locking pin 480 is overcome, the pin 480 is released fromwithin the opening 482 to allow relative movement between the first slatportion 454 a and the second slat portion 454 b. The spacing of theopenings 482 can be associated with specific dimensions of the bedsystem 400, and function as predetermined locking positions that a usermay use to easily transition the overall lengths of the slats 450 asneeded to create, for example, a twin-size mattress, which may then beextended further to accommodate a queen size mattress. The slats 450 maybe extended and selectively fixed at a desired length (i.e. bed size).

In another configuration, as illustrated in FIG. 30, the slats 450 areused with the bases 312 having the frame 352 rather than the frame 452that extends over a plurality of bases 412. For instance, the slats 450from one base 312 having the frame 352 to another base 312 having theframe 352 with a space between the adjacent bases 312. The mattressmodules 316 can still rest on the slats 450 even though a middle portionof the slats 450 are suspended above an open space between the adjacentbases 312. At least one side 490 of a base 312 may have a cutout ornotch 495 extending the entire length of the side 490 of the base 312.The width of the notch 495 may depend on the vertical thickness of theslats 450. The vertical thickness can be the distance between the uppersurface 64 of a slat 450 and the lower surface 66. The notch 495 canaccommodate the slats 450 so that the slats 450 may extend over thebases 312 and maintain an upper surface 64 that is flat and does notprotrude above the height of the base 312 when weight is applied to thebed system 300. In other words, when the slats 450 extend over the bases312, the top surface of the slats 450 provides a level surface, theheight of which may terminate at or before a top edge of the bases 312.

In another configuration, as illustrated in FIG. 31, not only are theslats adjustable but the frame and the base are adjustable in size, ordimensions of the frame and the base can be varied to accommodate alesser or greater number of mattress modules. As illustrated, a modularcomponent 510 includes a base 512 with a plurality of slats 550 (whichcan be similar to the slats 450 of FIG. 29). The base 512 is acombination of a base and frame described in earlier configurations orembodiments. The base and frame are segmented so that extension basemembers 520 can be added to the base 512 and increase a dimension of thebase 512; the dimension can be a length, width, or depth of the base512.

As illustrated, the base 512 includes walls 536 with frame segments 552having an exterior support 584, and interior support 586, and anintermediate support 592 similar to the other exterior supports,interior supports, and intermediate supports. In contrast to thepreviously described exterior supports, interior supports, andintermediate supports, the exterior support 584, the interior support586, and the intermediate support 592 extend partially around the base512. This accommodates for extension base member 520 that also includesthe exterior support 584, the interior support 586, and the intermediatesupport 592.

The extension base member 520 mounts to the walls 536 to position theframe segment 552 in alignment with the other frame segments 552. Theextension base member 520 can attach to the walls through attachmentfeatures 522, such as magnets, hook and loop fasteners, clips, othermechanical connectors, or the like. This allows a user to apply avariety of interchangeable, decorative panels or veneers (i.e. wood,faux wood, metal, patterns, etc.) to the exterior of the base 512.

The bed frame upon which the mattresses of the present invention restcan be a variety of different forms. FIG. 34A is one possible embodimentof an adjustable bed frame 800 that can be adjusted for use inconnection with different sized mattresses to form different sized bedswithout replacing the frame. Adjustable bed frame 800 is comprised ofadjustable, telescoping corners 804, which are selectively connected toone or more base modules 802 that have a uniform shape and size and thatcan be added to or removed from the frame system. In the example of FIG.34A, the bed frame 800 is a smaller bed frame, which is adjusted byextending the telescoping corners 804 to form a larger bed frame 830, asshown in FIG. 34B. The telescoping corner ends 804 can be extended inthe direction of the arrows 804 a as shown in FIG. 34B, to create alarger frame. In some embodiments, the inclusion of telescoping corners804 alone may be sufficient to extend a bed frame 800 to a desired size,while in other embodiments the addition or removal of base modules 802can be used in addition to, or instead of, telescoping corners 804 toadjust the size of the bed frame 800. The telescoping corners 804 may beextended and/or base modules 802 may be added to allow a user to createa bed frame capable of supporting various sizes of mattresses, such asthose discussed above.

The base modules 802, as shown in FIGS. 34A and 34B, all have the sameuniform size and configuration, such that there is uniformity andpredictability in substituting base modules. The exterior facing side ofthe base modules 802 can have aesthetic attachment features to allow auser to selectively attach and remove various veneers or finish panels.The finish panels may include wood panels, metal panels, plastic panels,fabric panels, or the like. The aesthetic attachment features cancomprise hook and loop fasteners, magnets, clips, hooks, snaps, buttons,or the like.

Additional base modules 802 can be added to or substituted from theoriginal set of base modules 802 of FIG. 34A in order to increase ordecrease the size of the bed frame 800 to a larger-size or smaller sizebed frame to accommodate a different sized mattress. For example, basemodules 802 can be removed from the bed frame 830, or bed frame 800, toform smaller beds.

The base modules 802 can be selectively secured together by couplers 808inserted into slits 806 on associated base modules 802. The telescopingcorners 804 can have slits 806 located at the telescoping corner ends804, which can maintain the connection between a corner end 804 and abase module 802 by use of a coupler 808 inserted into correspondingslits 806 on the base module 802 and corner end 804. This couplingmechanism can allow for the telescoping corners 804 to be extendedwithout having to detach them from adjacent base modules 802.

In some embodiments, the telescoping corners 804 can include mechanismswhich allow a user to extend a telescoping corner 804 and then lock itin place to maintain a specific size bed frame 800. The lockingmechanism can engage automatically upon the telescoping corner 804 beingextended to a particular length, or the locking mechanism can be engagedmanually by the user. The locking mechanism can include button clips,ball lock pins, clamps, telescoping clamps, twist lock clamps, or thelike.

The bed frame 800 has extendable, e.g., telescoping slats 810 thatextend when bed frame 800 is adjusted to be smaller or larger, asneeded. Slats 810 may be identical to or similar to the slats discussedpreviously herein. Slats 810 are configured to selectively mount withinthe securing edge 812 of the frame 800. Securing edge 812 may be anexample of a securing component for retaining (e.g., selectivelyretaining) a slat in contact with the bed frame 800. Securing edge 812may be similar to one or more features of the securing compartmentsdescribed above, such as a securing edge. For example, securingcompartments 100 having a securing edge 102, as described in previousembodiments relating to the lid, etc. may have features to be used insecuring edge 812 of FIGS. 34A-B. In some embodiments, the portion ofthe frame 800 comprising the securing edge 812 can also include aplurality of securing compartments, such as securing compartments 100 aspreviously described herein. Edge 812 may be an elongate groove or notchor a series of compartments configured to receive and retain individualslats in certain embodiments of edge 812.

The slats 810 can have similar retention member components at ends 814of slats 810 to the retention members discussed with respect to FIG. 5Babove, such that slats 810 are received by and retained on the bed frame800. The adjustable bed frame 800 can be conveniently extended andconfigured to accommodate different mattress sizes. The bed frame 800can have a variety of different forms, e.g., similar to bases 12, or inthe form of metallic rails or similar configurations.

Bed frame 800 can be made from any of the materials discussed above,such as polymer, wood, fiberglass, metal, alloys, composites, carbonfiber, and combinations thereof, or the like. The base modules 802comprising the adjustable bed frame 800 can comprise any of theaforementioned materials and can all be uniform in length. For example,the length of a base module can range from about 15.0″ to about 35.0″,or from about 20.0″ to about 30.0″, or from about 22.5″ to about 28.5″.

In one embodiment using the adjustable frame 800, a mattress system 850as shown in FIG. 35 can be mounted onto the adjustable bed frame 800.The mattress system 850 is comprised of a mattress 852 integrally-formedwith a spring system 854, which in the embodiment of FIG. 35 is aplurality of slats 856 molded integrally with the mattress 852 to form amattress/spring assembly. The integrated mattress/slats in FIG. 35 arepositioned within a cover 858, which may be a mattress topper, amattress casing, a shipping cover, or a variety of different covers suchas those discussed above for example.

The mattress 852 of system 850 may be comprised of a foam material, forexample, while the integrated slats of system 850 may be comprised ofthe same foam material formed in a different density or hardness.Optionally, different materials may be integrally-molded to form theintegrated mattress/spring assembly of FIG. 35.

One or more slats 856 form a spring system 854 that supports themattress 852 on a bed frame, such as adjustable bed frame 800. Thus, inone embodiment the slats 856, either within cover 858 or with cover 858removed, are selectively mounted onto respective securing edges 812 ofadjustable frame 800. Thus, slats 856 and mattress 852 can beintegrally-formed as a mattress/spring assembly in the form of a singlemolded member. The resulting single molded member can be selectivelymounted onto the adjustable frame 800 as a mattress/spring assembly.Cover 858 is selectively mounted on the mattress/spring assembly to formmattress system 850.

Following are some further example embodiments of the invention. Theseare presented only by way of example and are not intended to limit thescope of the invention in any way.

Embodiment 1

A furniture spring system, comprising a lid configured to provide aseating surface, the lid comprising a frame comprising two opposingframe members and a retention member associated with at least one of thetwo opposing frame members; a slat extending between the two opposingframe members, the slat comprising an elongate body having a first endand a second end and a catch disposed at the first end or second end;wherein the catch engages the retention member to retain the slat to theframe and the catch is configured to slide back-and-forth relative tothe retention member as a portion of the elongate body between the firstend and the second end elastically flexes downward and upward inresponse to forces intermittently pushing downward on the slat duringuse.

Embodiment 2

The furniture spring system as recited in Embodiment 1, wherein theframe comprises one or more securing compartments formed into a topsurface of each of the two opposing frame members.

Embodiment 3

The furniture spring system of any of Embodiments 1-2, wherein the catchcomprises a hooked end and the catch extends downwardly into one of theone or more securing compartments to retain the slat to the frame.

Embodiment 4

The furniture spring system of any of Embodiments 1-3, wherein theretention member is configured to prevent the catch from disengaging theretention member, the retention member is disposed above the securingcompartment and the catch, the retention member being configured toprevent the catch from lifting up and out of the securing compartment asthe portion of the slat elastically flexes downward and upward inresponse to forces intermittently pushing downward on the slat duringuse.

Embodiment 5

The furniture spring system of any of Embodiments 1-4, wherein theretention member comprises a bore extending upward from one of the twoopposing frame members.

Embodiment 6

The furniture spring system of any of Embodiments 1-5, wherein the catchcomprises an elongate opening extending through the elongate body into aterminal end of the first or second end of the slat and the bore extendsupward through the elongate opening to retain the slat to the frame.

Embodiment 7

The furniture spring system of any of Embodiments 1-6, wherein theretention member is configured to prevent the catch from disengagingfrom the frame, the retention member comprising a fastener inserted intothe bore, the retention member configured to prevent the catch fromlifting up and off of the bore as the middle portion of the slatelastically flexes downward and upward in response to forcesintermittently pushing downward on the slat during use.

Embodiment 8

The furniture spring system of any of Embodiments 1-7, wherein theretention member is configured to limit a back-and-forth slidingdistance of the catch relative to the retention member such that flexionof the slat is limited by the retention member.

Embodiment 9

The furniture spring system of any of Embodiments 1-8, wherein thespring system is configured to be mounted on a base frame of a furniturebase.

Embodiment 10

A furniture spring system, comprising a frame comprising two opposingframe members, and a retention member disposed on at last one of the twoopposing frame members, and elongate slat extending between the twoopposing frame members, the slat comprising an elongate body having anupper surface, a lower surface, a first end, a second end, and aflexible middle portion extending between the first end and the secondend, and a catch disposed at the first end or the second end, the catchengaging the retention member to retain the slat to the lid frame.

Embodiment 11

The furniture spring system of Embodiment 10, wherein the catch isconfigured to slide back-and-forth relative to the retention member asthe middle portion elastically flexes downward and upward in response toforces intermittently pushing downward on the slat during use.

Embodiment 12

The furniture spring system of any of Embodiments 10-11, wherein thelower surface of the slat is an arcuate surface such that the middleportion is thicker than the first and second ends of the slat.

Embodiment 13

The furniture spring system of any of Embodiments 10-12, wherein thespring system is configured to be mounted on a base frame of a furniturebase.

Embodiment 14

A furniture assembly, comprising a transverse member and a base member,the base member comprising a storage base and a lid configured to bemounted on a top of the storage base, such that the lid covers a storagecavity formed within the storage base, the lid comprising a frame withopposing frame members having one or more retention members, and one ormore slats, each slat having an elongate member and one or more catchesthat engage the one or more retention members of the frame.

Embodiment 15

The furniture assembly of Embodiment 14, wherein the engagement of theretention members with the catches limits a vertical distance of flexionof the slats such that the slats do not extend further into the storagecavity than the vertical distance of flexion, thus protecting objectsdisposed in the storage cavity during use.

Embodiment 16

The furniture assembly of any of Embodiments 14-15, wherein each slat ofthe lid comprises an arcuate profile along a longitudinal axis thereof.

Embodiment 17

The furniture assembly of any of Embodiments 14-16, wherein each of theone or more catches of each sat is disposed on an end of the slat.

Embodiment 18

The furniture assembly of any of Embodiments 14-17, further comprising aretention plate disposed above each end of each slat, the retentionplate being configured to prevent the one or more catches fromdisengaging the retention members of the lid when the slats flexdownward during use.

Embodiment 19

The furniture assembly of any of Embodiments 14-18, wherein the one ormore catches are configured to move back-and-forth relative to theretention members as the slats flex downward and upward during use.

Embodiment 20

A furniture spring system comprising, a lid configured to be mountedonto a base frame of a furniture base, the lid configured to provide aseating surface, the lid comprising, a frame comprising two opposingframe members, and a plurality of retention members associated with eachof the two opposing frame members, a plurality of slats extendingbetween the two opposing frame members, each of the slats comprising anelongate body having a first end and a second end and first and secondcatches disposed at the first end and second end, respectively, of theelongate body, wherein each catch engages a retention member to retainthe corresponding slat to the frame, and wherein each catch of a slat isconfigured to slide back-and-forth relative to the correspondingretention member as a portion of the elongate body between the first endand the second end elastically flexes downward and upward in response toforces intermittently pushing downward on the slat during use.

Embodiment 21

A modular mattress system, comprising a plurality of mattress modulesconfigured to form a first modular mattress of a first selected geometryand being reconfigurable to form a second modular mattress of a secondselected geometry, each of the mattress modules having a width (x) and alength (y), wherein the length (y) is substantially equal to two timesthe width (x); a bed casing (e.g., a rigid bed casing) configured tosecure the plurality of mattress modules to form a completed mattress;and a mattress topper sized and shaped to substantially cover thecompleted mattress and provide additional cushioning to a user.

Embodiment 22

The furniture spring system of Embodiment 21, wherein the second modularmattress also comprises one or more additional mattress modules having alength (y′) that is substantially equal to a length of the secondselected geometry.

Embodiment 23

The furniture spring system of any of Embodiments 21-22, wherein thesecond modular mattress comprises a greater quantity of mattress modulesthan that of the first modular mattress.

Embodiment 24

The furniture spring system of any of Embodiments 21-23, wherein the bedcasing (e.g., a rigid bed casing) is adjustable to selectively fit thefirst selected geometry and the second selected geometry.

Embodiment 25

The furniture spring system of any of Embodiments 21-24, wherein the bedcasing also comprises veneer side panels selectively secured to the bedcasing by magnets.

Embodiment 26

The furniture spring system of any of Embodiments 21-25, wherein themodular mattress system includes a casing applied to the plurality ofmattress modules, wherein the casing is sized and shaped to compensatefor missing length and/or width needed to form a standard size mattress.

Embodiment 27

A modular mattress system comprising, a plurality of mattress modulesconfigured to form a first modular mattress of a first selected geometryand being reconfigurable to form a second modular mattress of a secondselected geometry, each of the mattress modules having a width (x) and alength (y), wherein the length (y) is equal to two times the width (x),a bed casing configured to secure the plurality of mattress modules toform a completed mattress; and a mattress topper sized and shaped tocover the completed mattress and provide additional cushioning to auser.

The articles “a,” “an,” and “the” are intended to mean that there areone or more of the elements in the preceding descriptions. The terms“comprising,” “including,” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. Additionally, it should be understood that references to “oneembodiment” or “an embodiment” of the present disclosure are notintended to be interpreted as excluding the existence of additionalembodiments that also incorporate the recited features. Numbers,percentages, ratios, or other values stated herein are intended toinclude that value, and also other values that are “about” or“approximately” the stated value, as would be appreciated by one ofordinary skill in the art encompassed by embodiments of the presentdisclosure. A stated value should therefore be interpreted broadlyenough to encompass values that are at least close enough to the statedvalue to perform a desired function or achieve a desired result. Thestated values include at least the variation to be expected in asuitable manufacturing or production process, and may include valuesthat are within 5%, within 1%, within 0.1%, or within 0.01% of a statedvalue.

A person having ordinary skill in the art should realize in view of thepresent disclosure that equivalent constructions do not depart from thespirit and scope of the present disclosure, and that various changes,substitutions, and alterations may be made to embodiments disclosedherein without departing from the spirit and scope of the presentdisclosure. Equivalent constructions, including functional“means-plus-function” clauses are intended to cover the structuresdescribed herein as performing the recited function, including bothstructural equivalents that operate in the same manner, and equivalentstructures that provide the same function. It is the express intentionof the applicant not to invoke means-plus-function or other functionalclaiming for any claim except for those in which the words ‘means for’appear together with an associated function. Each addition, deletion,and modification to the embodiments that falls within the meaning andscope of the claims is to be embraced by the claims.

The terms “approximately,” “about,” and “substantially” as used hereinrepresent an amount close to the stated amount that still performs adesired function or achieves a desired result. For example, the terms“approximately,” “about,” and “substantially” may refer to an amountthat is within less than 10% of, within less than 5% of, within lessthan 1% of, within less than 0.1% of, and within less than 0.01% of astated amount. Further, it should be understood that any directions orreference frames in the preceding description are merely relativedirections or movements. For example, any references to “up” and “down”or “above” or “below” are merely descriptive of the relative position ormovement of the related elements.

The present invention may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. The describedembodiments are to be considered in all respects only as illustrativeand not restrictive. The scope of the invention is, therefore, indicatedby the appended claims rather than by the foregoing description. Allchanges that come within the meaning and range of equivalency of theclaims are to be embraced within their scope.

What is claimed is:
 1. A furniture spring system, comprising: a lidconfigured to provide a seating surface, the lid comprising: a framecomprising two opposing frame members; and a retention member associatedwith at least one of the two opposing frame members; a slat extendingbetween the two opposing frame members, the slat comprising: an elongatebody having a first end and a second end; and a catch disposed at thefirst end or second end; wherein the catch engages the retention memberto retain the slat to the frame; wherein the catch is configured toslide back-and-forth relative to the retention member as a portion ofthe elongate body between the first end and the second end elasticallyflexes downward and upward in response to forces intermittently pushingdownward on the slat during use; wherein the frame comprises one or moresecuring compartments formed into a top surface of each of the twoopposing frame members.
 2. The spring system of claim 1, wherein: thecatch comprises a hooked end; and the catch extends downwardly into oneof the one or more securing compartments to retain the slat to theframe.
 3. The spring system of claim 2, wherein the retention member isconfigured to prevent the catch from disengaging the retention member,the retention member is disposed above the securing compartment and thecatch, the retention member being configured to prevent the catch fromlifting up and out of the securing compartment as the portion of theslat elastically flexes downward and upward in response to forcesintermittently pushing downward on the slat during use.
 4. The springsystem of claim 1, wherein the retention member comprises a boreextending upward from one of the two opposing frame members.
 5. Thespring system of claim 4, wherein: the catch comprises an elongateopening extending through the elongate body into a terminal end of thefirst or second end of the slat; and the bore extends upward through theelongate opening to retain the slat to the frame.
 6. The spring systemof claim 5, wherein the retention member is configured to prevent thecatch from disengaging from the frame, the retention member comprising afastener inserted into the bore, the retention member configured toprevent the catch from lifting up and off of the bore as the middleportion of the slat elastically flexes downward and upward in responseto forces intermittently pushing downward on the slat during use.
 7. Thespring system of claim 1, wherein the retention member is configured tolimit a back-and-forth sliding distance of the catch relative to theretention member such that flexion of the slat is limited by theretention member.
 8. The spring system of claim 1, wherein the springsystem is configured to be mounted on a base frame of a furniture base.9. A furniture spring system, comprising: a frame comprising twoopposing frame members; and a retention member disposed on at least oneof the two opposing frame members; an elongate slat extending betweenthe two opposing frame members, the slat comprising: an elongate bodyhaving an upper surface, a lower surface, a first end, a second end, anda flexible middle portion extending between the first end and the secondend; and a catch disposed at the first end or the second end, the catchengaging the retention member to retain the slat to the frame, whereinthe frame comprises one or more securing compartments formed into a topsurface of each of the two opposing frame members.
 10. The furniturespring system of claim 9, wherein the catch is configured to slideback-and-forth relative to the retention member as the middle portionelastically flexes downward and upward in response to forcesintermittently pushing downward on the slat during use.
 11. Thefurniture spring system of claim 9, wherein the lower surface of theslat comprises an arcuate surface such that the middle portion isthicker than the first end and the second end of the slat.
 12. Thefurniture spring system of claim 9, wherein the spring system isconfigured to be mounted on a base frame of a furniture base.
 13. Afurniture assembly comprising: a transverse member; a base member, thebase member comprising: a storage base; and a lid configured to bemounted on a top of the storage base, such that the lid covers a storagecavity formed within the storage base, the lid comprising: a frame withopposing frame members having one or more retention members, and one ormore slats, each slat having an elongate member and one or more catchesthat engage the one or more retention members of the frame; and aretention plate disposed above each end of each slat, the retentionplate being configured to prevent the one or more catches fromdisengaging the retention members of the lid when the slats flexdownward during use.
 14. The furniture assembly of claim 13, wherein theengagement of the retention members with the catch limits a verticaldistance of flexion of the slats such that the slats do not extendfurther into the storage cavity than the vertical distance of flexion,thus protecting objects disposed in the storage cavity during use.
 15. Afurniture assembly as recited in claim 13, wherein each slat of the lidcomprises an arcuate profile along a longitudinal axis thereof.
 16. Afurniture assembly as recited in claim 13, wherein each of the one ormore catches of each slat is disposed on an end of the slat.
 17. Afurniture assembly as recited in claim 13, wherein the one or morecatches are configured to move back-and-forth relative to the retentionmembers as the slats flex downward and upward during use.
 18. Afurniture spring system, comprising: a lid configured to be mounted ontoa base frame of a furniture base, the lid configured to provide aseating surface, the lid comprising: a frame comprising two opposingframe members; and a plurality of retention members associated with eachof the two opposing frame members; a plurality of slats extendingbetween the two opposing frame members, each of the slats comprising: anelongate body having a first end and a second end; and first and secondcatches disposed at the first end and second end, respectively, of theelongate body; wherein each catch engages a retention member to retainthe corresponding slat to the frame; wherein each catch of a slat isconfigured to slide back-and-forth relative to the correspondingretention member as a portion of the elongate body between the first endand the second end elastically flexes downward and upward in response toforces intermittently pushing downward on the slat during use, andwherein the frame comprises one or more securing compartments formedinto a top surface of each of the two opposing frame members.
 19. Afurniture spring system, comprising: a lid configured to provide aseating surface, the lid comprising: a frame comprising two opposingframe members; and a retention member associated with at least one ofthe two opposing frame members; a slat extending between the twoopposing frame members, the slat comprising: an elongate body having afirst end and a second end; and a catch disposed at the first end orsecond end; wherein the catch engages the retention member to retain theslat to the frame; wherein the catch is configured to slideback-and-forth relative to the retention member as a portion of theelongate body between the first end and the second end elasticallyflexes downward and upward in response to forces intermittently pushingdownward on the slat during use; and wherein the retention membercomprises a bore extending upward from one of the two opposing framemembers.
 20. A furniture spring system, comprising: a frame comprisingtwo opposing frame members; and a retention member disposed on at leastone of the two opposing frame members; an elongate slat extendingbetween the two opposing frame members, the slat comprising: an elongatebody having an upper surface, a lower surface, a first end, a secondend, and a flexible middle portion extending between the first end andthe second end; and a catch disposed at the first end or the second end,the catch engaging the retention member to retain the slat to the frame;wherein the lower surface of the slat comprises an arcuate surface suchthat the middle portion is thicker than the first end and the second endof the slat.
 21. A furniture spring system, comprising: a framecomprising two opposing frame members; and a retention member disposedon at least one of the two opposing frame members; an elongate slatextending between the two opposing frame members, the slat comprising:an elongate body having an upper surface, a lower surface, a first end,a second end, and a flexible middle portion extending between the firstend and the second end; and a catch disposed at the first end or thesecond end, the catch engaging the retention member to retain the slatto the frame; a retention plate disposed above each end of the elongatedslat, the retention plate being configured to prevent the catch fromdisengaging the retention member when the slat flexes downward duringuse.
 22. A furniture spring system, comprising: a lid configured toprovide a seating surface, the lid comprising: a frame comprising twoopposing frame members; and a retention member associated with at leastone of the two opposing frame members; and a slat extending between thetwo opposing frame members, the slat comprising: an elongate body havinga first end and a second end; a catch disposed at the first end orsecond end; and the first end and the second end of the elongate bodyhaving a hole or a slot therein; wherein the catch engages the retentionmember to retain the slat to the frame; wherein the catch is configuredto slide back-and-forth relative to the retention member as a portion ofthe elongate body between the first end and the second end elasticallyflexes downward and upward in response to forces intermittently pushingdownward on the slat during use; and wherein the retention membercomprises a protrusion configured to engage in the hole or the slot inthe slat to retain the slat in place.